Foldable building structures with utility channels and laminate enclosures

ABSTRACT

An enclosure component having a thickness for a building structure having an interior sheathing layer comprising paper; a first structural layer bonded to the interior sheathing layer and comprising a first generally rectangular structural panel of magnesium oxide arranged in a side-by-side relationship with a second generally rectangular structural panel of magnesium oxide to define a first structural panel seam between the first and second structural panels. There is a first binding strip of magnesium oxide positioned over the first structural panel seam and fastened to form a lap joint with the first structural panel and with the second structural panel, so as to bond together the first and second structural panes. The enclosure component includes a first strengthening layer, comprising woven fiber mat, bonded to the first structural layer; and a foam layer with first and second opposing faces comprising a first generally rectangular foam panel and a second generally rectangular foam panel arranged in a side-by-side relationship to define a foam panel seam between the first and second foam panels. The first structural panel seam is offset from the foam panel seam a select distance in a direction generally perpendicular to the thickness. The first strengthening layer is bonded to the first opposing face of the foam layer. The enclosure component also has a second structural layer comprising a third generally rectangular structural panel of magnesium oxide arranged in a side-by-side relationship with a fourth generally rectangular structural panel of magnesium oxide to define a second structural panel seam between the third and fourth structural panels. There is a second binding strip of magnesium oxide positioned over the second structural panel seam and fastened to form a lap joint with the third structural panel and with the fourth structural panel, so as to bond together the third and fourth structural panels. The second structural panel seam is offset from the foam panel seam a select distance in a direction generally perpendicular to the thickness; and the second structural layer is bonded to the second opposing face of the foam layer.

CROSS-REFERENCES TO RELATED APPLICATIONS

The present application is a divisional of U.S. Non-Provisionalapplication Ser. No. 16/786,130, filed Feb. 10, 2020 which claims thebenefit of U.S. Provisional Application No. 62/805,710, filed Feb. 14,2019 and U.S. Provisional Application No. 62/960,991, filed Jan. 14,2020.

BACKGROUND OF THE INVENTION Field of the Invention

The inventions herein relate to structures, such as dwellings and otherbuildings for residential occupancy, commercial occupancy and/ormaterial storage, which are foldable for facilitating transport, and tocomponents for such structures.

Description of the Related Art

In the field of residential housing, the traditional technique forbuilding homes is referred to as “stick-built” construction, where abuilder constructs housing at the intended location using in substantialpart raw materials such as wooden boards, plywood panels, and steelLally columns. The materials are assembled piece by piece over apreviously prepared portion of ground, for example, a poured concreteslab or a poured concrete or cinder block foundation.

There have been a variety of efforts to depart from the conventionalconstruction techniques used to create dwellings, as well as commercialspaces and like. One of the alternatives to stick-built construction isvery generally referred to as modular housing. As opposed to stick-builtconstruction, where the structure is built on-site, a modular house isconstructed in a factory and then shipped to the site, often by means ofa tractor-trailer. A drawback of modular housing is that the prospectivebuyer can customize the structure layout only to a relatively limiteddegree. That is, while certain features, for example a closet, may beadded or subtracted from a room, the general shape and layout of thehouse cannot be changed or adapted to the customer's preference.

Additionally, modular housing often exceeds in size normally-permittedlegal limits for road transport. For example, in the United States themaximum permitted dimensions for road transport are in general 102inches (259.1 cm) in width, 13.5 feet (4.11 m) in height and 65 to 75feet (19.81 to 22.86 m) in length. Thus, in many cases transporting amodular house from factory to site requires oversize load permits, whichmay impose restrictions on when transport can be undertaken and whatroutes can be utilized. Oversize road regulations may also require theuse of an escort car and a trailing car as well. All of theserequirements and restrictions inevitably increase the cost of themodular housing.

Another alternative to stick-built construction is what is commonlyreferred to as a mobile home or trailer home. Mobile and trailer homes,like modular housing, are constructed in a factory and then transportedto the intended location. They can be configured as two or threeseparate pieces which are joined at the receiving location, in whichcase they are referred to in the United States as a double-wide or atriple wide. Mobile and trailer homes often require less on-sitefinishing prior to occupancy than modular housing. On the other hand,such homes generally are almost always single story, tend to have alimited floor plan essentially dictated by transport requirements, andoften cannot be customized by the buyer to any substantial degree. Likemodular houses, mobile and trailer homes often exceed oversize roadregulations with the attendant drawbacks described above.

A still further alternative approach to stick-built construction is toutilize panels (not entire houses or rooms) which are fabricated in afactory and transported to a building site for assembly into a structureand finishing. In particular, such panels are referred to as structuralinsulated panels, or SIPs for short. A SIPs panel typically is a foamcore panel faced on each side with a structural board, such as orientedstrand board. Using SIPs in construction is often regarded as of limitedbenefit relative to stick-built construction, because the finishing ofthe house, as opposed to the framing, is generally the most expensivepart of construction. Also, in the case where multiple SIPs are used toform for example a wall, the intersection between two adjacent SIPs willhave a seam across the thickness of the wall, which can impactstructural rigidity. In addition, when apertures are cut in orpositioned on-site with SIPs for placement of windows and doors, thebuilder must insert a lintel or header across the top of each apertureto distribute vertical loads imposed from above each window and door tothe load-bearing sides. This too increases the costs of using SIPs.

There are also temporary offices, or site trailers, which are similar indimension to a trailer house. Temporary offices are typically renderedin steel, and are simply sheltered locations containing storage, officeand meeting areas. They are not suitable for permanent residency oroccupancy.

Significant advancements in the construction of dwellings and commercialspace are described in U.S. Pat. Nos. 8,474,194, 8,733,029 and U.S.Patent Publication No. 2019/0100908. In one aspect, those patentdocuments pertain to fabricating wall, floor and ceiling components in afactory that are folded together into a compact shipping module, andwhich are then transported to the intended location and unfolded toyield a structure, where the folding and unfolding of the components canbe facilitated by the use of hinges.

SUMMARY OF THE INVENTION

The present inventions provide a set of wall, floor and ceilingcomponents that can be fabricated in a factory and delivered to aconstruction site, where they can be assembled into structures suitablefor human or material occupancy, such as housing, offices, retail space,and warehouse use. The components described herein can be easily shippedfrom a factory to a construction site. Moreover, the wall components arestructured to support all designed-for vertical loads in theiras-delivered state, yet can be customized on-site with doors and windowsin an open-ended variety of styles, notwithstanding their factory-builtnature. Additionally, the finished structures made in accordance withthe inventions disclosed herein can be assembled in a multitude ofconfigurations. Thus these inventions advantageously accord the userboth the advantages of individualized customized construction and theefficiency and economy of factory fabrication.

One aspect of one of the present inventions is directed to an enclosurecomponent for a building structure, the enclosure component having athickness and comprising an interior sheathing layer comprising paper; afirst structural layer bonded to the interior sheathing layer, where thefirst structural layer comprises a first generally rectangularstructural panel of magnesium oxide arranged in a side-by-siderelationship with a second generally rectangular structural panel ofmagnesium oxide to define a first structural panel seam between thefirst and second structural panels, and where the first structural layerincludes a first binding strip positioned over the first structuralpanel seam and fastened to form a lap joint with the first structuralpanel and with the second structural panel, so as to bond together thefirst and second structural panels. The enclosure component includes afirst strengthening layer comprising woven fiber mat, the firststrengthening layer is bonded to the first structural layer; and a foamlayer with first and second opposing faces comprising a first generallyrectangular foam panel and a second generally rectangular foam panelarranged in a side-by-side relationship to define a foam panel seambetween the first and second foam panels; where the first and secondstructural panels are positioned relative to the first and second foampanels such that the first structural panel seam is offset from the foampanel seam a select distance in a direction generally perpendicular tothe thickness; and the first strengthening layer is bonded to the firstopposing face of the foam layer.

The foregoing enclosure component additionally includes a secondstructural layer comprising a third generally rectangular structuralpanel of magnesium oxide arranged in a side-by-side relationship with afourth generally rectangular structural panel of magnesium oxide todefine a second structural panel seam between the third and fourthstructural panels, and where the second structural layer includes asecond binding strip positioned over the second structural panel seamand fastened to form a lap joint with the third structural panel andwith the fourth structural panel, so as to bond together the third andfourth structural panels. The third and fourth structural panels arepositioned relative to the first and second foam panels such that thesecond structural panel seam is offset from the foam panel seam a selectdistance in a direction generally perpendicular to the thickness; andthe second structural layer is bonded to the second opposing face of thefoam layer.

Another aspect of one of the present inventions is directed to afoldable building structure that comprises a fixed space portion thatincludes a first floor portion having a thickness to define an interiorportion of the first floor portion, a first ceiling portion having athickness to define an interior portion of the first ceiling portion,and a first wall portion having a thickness to define an interiorportion of the first wall portion. The foldable building structurefurther comprises a second ceiling portion having a thickness to definean interior portion of the second ceiling portion, the second ceilingportion movable between a folded position that is proximate to the fixedspace portion and a deployed position, and a third ceiling portionhaving a thickness to define an interior portion of the third ceilingportion, the third ceiling portion movable between a folded positionthat is proximate to the fixed space portion and a deployed position.The second and third ceiling portions are movable from their respectivefolded positions to their respective deployed positions to form aceiling component of the building structure when deployed, where theceiling component has a periphery. The first, second and third ceilingportions each define sections of a utility channel in the interiorportions of the first, second and third ceiling portions, which sectionsare configured to form a closed loop utility channel in the interiorportions of the ceiling component when the second and third ceilingportions are in their deployed positions, the utility channel beinglocated proximate the periphery of the ceiling component and adapted forcontaining utility lines.

These and other aspects of the present inventions are described in thedrawings annexed hereto, and in the description of the preferredembodiments and claims set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are perspective views of finished structures prepared inaccordance with the present inventions.

FIGS. 2A and 2B are top schematic views of finished structures preparedin accordance with the present inventions.

FIGS. 3A and 3B are end views of shipping modules from which are formedthe finished structures respectively shown in FIGS. 1A and 1B.

FIGS. 4A, 4B, 4C and 4D are exploded cross-sectional views of fourembodiments of laminate multi-layer constructions for use in theenclosure components of the present inventions.

FIG. 5A is a cutaway perspective interior view of a wall component inaccordance with the present inventions, FIG. 5B is a cutaway perspectiveexterior view of a wall component in accordance with the presentinventions, and FIG. 5C is a cutaway view of a wall component depictingan arrangement of wall chases in accordance with the present inventions.

FIGS. 6A and 6B are partial cutaway perspective views of a finishedstructure in accordance with the present inventions, depicting ingreater detail aspects of the ceiling, wall and floor components of afirst type of structure in accordance with the present inventions.

FIGS. 6C and 6D are partial cutaway views of a finished structure inaccordance with the present inventions, depicting in greater detail thebuilt-up utility channel embodiment of the utility service system of thepresent inventions.

FIG. 6E is an underside plan view of a ceiling component of the presentinvention, which includes a built-up utility channel embodiment of theutility service system of the present inventions.

FIGS. 7A and 7B are partial cutaway views of a finished structure inaccordance with the present inventions, depicting in greater detailaspects of the ceiling, wall and floor components of a second type ofstructure in accordance with the present inventions.

FIG. 7C is a partial cutaway perspective view of a finished structure inaccordance with the present inventions, depicting in greater detail theconstruction of a ceiling component, which utilizes an in situ utilitychannels embodiment of the utility service system of the presentinvention, and depicting the juncture of the ceiling component with awall component.

FIG. 7D is a cutaway plan view of a ceiling component of the presentinvention, which includes an in situ utility channels embodiment of theutility service system and the ceiling chases of the present inventions,and FIG. 7E is a perspective view of an in situ channels embodiment ofthe utility service system of the present inventions depicting a channelaccess plate.

FIG. 7F is a cutaway plan view of a floor component that depicts thefloor chases of the present inventions.

FIG. 8 is a schematic side view of an embodiment of a hinge structurejoining two floor portions in accordance with the present inventions.

FIG. 9 is a schematic side view of an embodiment of a hinge structurejoining two roof portions in accordance with the present inventions.

FIG. 10 depicts the layout of a three room structure fabricated inaccordance with the present inventions.

FIG. 11 is a perspective view of a two story structure fabricated inaccordance with the present inventions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1A depicts a finished structure 150 of a first type (sometimesreferred to herein as type 1 structure 151) in accordance with theinventions disclosed herein, and FIG. 1B depicts a finished structure150 of a second type (sometimes referred to herein as type 2 structure152) in accordance with the inventions disclosed herein. Type 1structure 151 is smaller than type 2 structure 152, but the inventionsdescribed herein are equally applicable to the fabrication anddeployment of type 1 structure 151, type 2 structure 152, and to otherstructures of different dimensions as well. Accordingly, referencesherein to “structure 150” should be understood to generically denotetype 1 structure 151 and type 2 structure 152 without distinction.Likewise, reference in this disclosure to the same numericallyidentified component among different embodiments indicates that suchcomponent is the same among such different embodiments.

Structure 150 as depicted in FIGS. 1A and 1B has a rectangular shapemade of three types of generally planar and rectangular enclosurecomponents 155, the three types of enclosure components 155 consistingof a wall component 200, a floor component 300, and a ceiling component400. Structure 150 has one floor component 300, one ceiling component400 and four wall components 200. As shown in FIGS. 1A and 1B, theperimeter of finished structure 150 is defined by first longitudinaledge 106, first transverse edge 108, second longitudinal edge 116 andsecond transverse edge 110.

Enclosure components 155 (wall component 200, floor component 300, andceiling component 400) can be fabricated and dimensioned as describedherein and positioned together to form a shipping module 100, shownend-on in FIGS. 3A and 3B, with FIG. 3A depicting a shipping module 100for a type 1 structure 151 and FIG. 3B depicting a shipping module 100for a type 2 structure 152. The enclosure components 155 are dimensionedso that the shipping module 100 is within U.S. federal highwaydimensional restrictions. As a result, shipping module 100 can betransported over a limited access highway more easily, and withappropriate trailering equipment, transported without the need foroversize permits. Thus, the basic components of finished structure 150can be manufactured in a factory, positioned together to form theshipping module 100, and the modules 100 can be transported to thedesired site for the structure, where they can be readily assembled andcustomized, as described herein.

Enclosure Component Laminate Design

A laminate multi-layer design can be used to fabricate the enclosurecomponents 155 of the present inventions. FIGS. 4A-4D depict fourembodiments of that multi-layer design, in exploded cross-section, foran exemplary enclosure component 155.

First and Second Embodiments

Interior Sheathing Layer (282). In the first and second embodiments ofthe laminate multi-layer design, shown in FIGS. 4A and 4B respectively,the surface of enclosure component 155 that will face toward theinterior of structure 150 is optionally provided with an interiorsheathing layer 282. It is preferred that interior sheathing layer 282be fabricated of relatively thick paper, of a weight comparable to thatused as the exterior surface of drywall (marketed for example under thetrademark Sheetrock®). Interior sheathing layer 282 preferably isunrolled from a continuous roll of paper (the paper roll optionallyhaving a width approximating the width of enclosure component 155) toyield a seamless interior finish for enclosure component 155. Thisadvantageously compares to conventional construction techniques, whetherstick-built, SIPs or steel construction, wherein sheets of drywall firstmust be secured to structural elements, and then the seams betweenadjacent sheets must be given a smooth transition by applying mortarsuch as spackling compound followed by sanding. These expensive andlaborious steps of interior finishing can be avoided by employing, inaccordance with the teachings of this disclosure, a continuous roll ofpaper to fabricate interior sheathing layer 282. Likewise, there is noneed to use for example drywall for finishing.

First Structural Layer (210). A first structural layer 210 is providedin the first embodiment depicted in FIG. 4A and in the second embodimentdepicted in FIG. 4B. If used, the interior sheathing layer 282 is bondedto this first structural layer 210 with a suitable adhesive, preferablya polyurethane based construction adhesive. First structural layer 210in the embodiments shown comprises a plurality of rectangular structuralbuilding panels 211 principally comprising an inorganic composition ofrelatively high strength, such as magnesium oxide (MgO). Suitablestructural building panels 211 can be MgO boards approximately four feet(1.22 m) wide by approximately eight feet (2.44 m) long. In a specificimplementation of the first embodiment of the multi-layer design of FIG.4A, the thickness of those structural building panels 211 usingmagnesium oxide board can be approximately 0.5 inch (1.27 cm); as analternative, a thickness of approximately 0.25 inch (0.64 cm) can beemployed.

To form first structural layer 210, a number of generally rectangularstructural building panels 211 are laid adjacent to each other togenerally cover the full area of the intended enclosure component 155.For example, for the wall component 200 a shown in FIG. 5A, structuralbuilding panels 211 are arranged horizontally and vertically adjacenteach other in a checkerboard relationship to generally cover the fullarea of wall component 200 a. As another exemplary arrangement, a numberof structural building panels 211 of sufficient length can be verticallypositioned side-by-side to generally cover the full area of a wallcomponent 200.

First structural layer 210 in the first and second embodiments,respectively shown in FIGS. 4A and 4B, additionally comprises multiplebinding strips 212, made for example of magnesium oxide board, laid bothhorizontally and/or vertically as appropriate. In particular, bindingstrips 212 are positioned over the linear junctions between adjacentpanels 211, and then are fastened to the regions of those panelsbordering those junctions, using for example a suitable adhesive,preferably a polyurethane based construction adhesive, to form a lapjoint between the adjacent building panels 211, thereby bonding togetherthe panels 211 of first structural layer 210 to form a single unit.Binding strips 212 of magnesium oxide board can be for exampleapproximately six inches (15.2 cm) wide and 0.25 inch (0.635 cm) or 0.5inch (1.27 cm) thick.

First Strengthening Layer (213-1). As shown in the first and secondembodiments depicted in FIGS. 4A and 4B respectively, there is nextprovided a first strengthening layer 213-1, made of woven fiber such aswoven fiberglass. In the first embodiment, shown in FIG. 4A, firststrengthening layer 213-1 preferably is unrolled from a continuous rollof mat (the mat roll optionally having a width approximating the widthof enclosure component 155) to yield a seamless interior layer. In thesecond embodiment, shown in FIG. 4B, first strengthening 213-1 comprisesmultiple separate fiber layer segments, as exemplified by segments 213-1a and 213-1 b shown in FIG. 4B, which are positioned between bindingstrips 212.

Foam Panels (214). Referring again to FIGS. 4A and 4B, there is nextprovided in the first and second embodiments a plurality of generallyplanar rectangular foam panels 214 collectively presenting a first faceand a second opposing face. Foam panels 214 are made for example ofexpanded polystyrene (EPS) or polyurethane foam. A number of these foampanels 214 are laid adjacent to each other to generally cover the fullarea of the intended enclosure component 155. For example, for the wallcomponent 200 a shown in FIG. 5B, foam panels 214 are arrangedhorizontally and vertically adjacent each other in a checkerboardrelationship to generally cover the full area of wall component 200 a.As another exemplary arrangement, a number of foam panels 214 ofsufficient length can be vertically positioned side-by-side to generallycover the full area of a wall component 200.

It is preferred that the seams between adjacent foam panels 214 notoverlay or coincide with the seams between the structural buildingpanels 211 of first structural layer 210, in reference to the directionacross the thickness of the enclosure component 155. Rather, it ispreferred that the seams between adjacent foam panels 214 be offset adistance from the seams between adjacent structural building panels 211of first structural layer 210. For example, for foam panels 214vertically positioned side-by-side and structural building panels 211vertically positioned side-by-side, the seams between adjacent foampanels can be positioned at or as near the mid-line (the middle dividingline) of structural building panels 211 as design, manufacturing andother considerations permit. Correspondingly, for foam panels 214arranged in a checkerboard relationship and building panels 211 arrangedin a checkerboard relationship, each corner where four foam panels 214meet can be positioned at or as near the center of a structural buildingpanel 211 as design, manufacturing and other considerations permit.

First strengthening layer 213-1 preferably is sandwiched between andfastened to both first structural layer 210 and to the first face offoam panels 214 using a suitable adhesive, preferably a polyurethanebased construction adhesive. If the woven fiber of first strengtheninglayer 213-1 has a relatively open weave, only one adhesive spread isrequired during manufacture to bond together the layers 210, 213-1 and214 into a bonded laminate structure.

Foam panels 214 impart both thermal insulation and contribute toresistance of compressive loads imposed on enclosure component 155, suchas those that may be borne by a wall from roof and upper floor loads.First strengthening layer 213-1 imparts strength to enclosure component155, as well as acts as a burst barrier against weather-drivenprojectiles that would otherwise create a risk of wall penetration.Adjacent foam panels 214 optionally can be fastened to each other with asuitable adhesive applied between abutting panels, preferably apolyurethane based construction adhesive.

Second Strengthening Layer (213-2). In the first embodiment of thelaminate multi-layer design shown in FIG. 4A, there is a strengtheninglayer of woven fiber, first strengthening layer 213-1, on one face offoam panels 214 only. In the second embodiment of the laminatemulti-layer design, shown in FIG. 4B, there is a second strengtheninglayer 213-2, made of woven fiber such as woven fiberglass, on the secondopposing face of foam panels 214. Second strengthening layer 213-2 canbe continuous, like first strengthening layer 213-1 shown in FIG. 4A, orcan comprise multiple separate fiber layer segments, as exemplified bysegments 213-2 a and 213-2 b shown in FIG. 4B, which are positionedbetween binding strips 217, described further below.

Second Structural Layer (215). In the first embodiment of the laminatemulti-layer design shown in FIG. 4A, there is provided a secondstructural layer 215, which is positioned on the second opposing face offoam panels 214 (the face distal from first structural layer 210). Inthe second embodiment of the laminate multi-layer design, shown in FIG.4B, there is also provided a second structural layer 215, although inthis second embodiment the second strengthening layer 213-2 issandwiched between the second opposing face of foam panels 214 andsecond structural layer 215. Second structural layer 215 comprises aplurality of rectangular structural building panels 216, eachprincipally comprising an inorganic composition of relatively highstrength, such as magnesium oxide. Suitable building panels 216 can bemagnesium oxide boards approximately four feet (1.22 m) wide by eightfeet (2.44 m) long. In an exemplary embodiment of second structurallayer 215, the thickness of those structural building panels 216 usingmagnesium oxide board can approximately 0.5 inch (1.27 cm) as analternative, a thickness of approximately 0.25 inch (0.64 cm) can beemployed.

To form second structural layer 215, a number of rectangular structuralbuilding panels 216 are laid adjacent to each other to generally coverthe full area of the intended enclosure component 155. For example, forthe wall component 200 a shown in FIG. 5B, structural building panels216 are arranged horizontally and vertically adjacent each other in acheckerboard relationship to generally cover the full area of wallcomponent 200 a. As another exemplary arrangement, a number ofstructural building panels 216 of sufficient length can be verticallypositioned side-by-side to generally cover the full area of a wallcomponent 200.

As is the case for first structural layer 210, it is preferred that theseams between adjacent foam panels 214 not overlay or coincide with theseams between the structural building panels 216 of second structurallayer 215 in the direction across the thickness of the enclosurecomponent 155. Rather, it is preferred that the seams between adjacentfoam panels 214 be offset a distance from the seams between adjacentstructural building panels 216 of second structural layer 215. Forexample, for foam panels 214 vertically positioned side-by-side andstructural building panels 216 vertically positioned side-by-side, theseams between adjacent foam panels 214 can be positioned at or as nearthe mid-line of structural building panels 216 as design, manufacturingand other considerations permit. Correspondingly, for foam panels 214arranged in a checkerboard relationship and structural building panels216 arranged in a checkerboard relationship, each corner where four foampanels 214 meet can be positioned at or as near the center of astructural building panel 216 as design, manufacturing and otherconsiderations permit. On the other hand, the seams between thestructural building panels 211 of first structural layer 210 cancoincide without preference in the direction across the thickness of theenclosure component 155 with the seams of structural building panels 216of second structural layer 215.

The second structural layer 215 in the first and second embodiments,shown in FIGS. 4A and 4B respectively, additionally comprises multiplebinding strips 217, made for example of magnesium oxide board,positioned between building panels 216 and foam panels 214. Bindingstrips 217 are positioned over the linear junctions between adjacentpanels 216, and then are fastened to the regions of those panelsbordering those junctions, using for example a suitable adhesive,preferably a polyurethane based construction adhesive, to form a lapjoint between the adjacent building panels 216, thereby bonding togetherthe panels 211 of first structural layer 210 to form a single unit.Binding strips 217 of magnesium oxide board can be for exampleapproximately six inches (15.2 cm) wide and 0.25 inches (0.635 cm) or0.5 inch (1.27 cm) thick.

If first strengthening layer 213-1 and/or second strengthening layer213-2 are formed from a continuous roll, then foam panels 214 can beprovided with suitable recesses (not shown) to accommodate such localthickness variations of the combination of layer 213-1/binding strips212 and/or layer 213-2/binding strips 217 as may arise in the regionsproximate the binding strips. If first strengthening layer 213-1 and/orsecond strengthening layer 213-2 are formed from separate segments, thenfoam panels 214 can be provided with suitable recesses (not shown) toreceive binding strips 212 and/or 217.

In the first embodiment shown in FIG. 4A, second structural layer 215 isfastened to foam panels 214 using for example a suitable adhesive,preferably a polyurethane based construction adhesive. In the secondembodiment shown in FIG. 4B, second strengthening layer 213-2 preferablyis fastened to both second structural layer 215 and to foam panels 214using for example a suitable adhesive, preferably a polyurethane basedconstruction adhesive. If first strengthening layer 213-2 has a wovenfiber having a relatively open weave, only one adhesive spread isrequired during manufacture to bond together the layers 214, 213-2 and215 into a bonded laminate structure.

In the embodiment of wall component 200 shown in FIG. 5B, the exteriorof the structural building panels 216 of second structural layer 215 areprovided with grooves 218 for aesthetic reasons, particularly to betterconceal the presence of the seams between adjacent panels 216.Optionally, the exterior of panels 216 can be covered with additionalprotective material unrolled from a continuous roll.

The first embodiment of the laminate multi-layer design, shown in FIG.4A, is particularly suitable where tensile loads (such as may arise fromloads inducing flexing or bending) are experienced by the combination offirst structural layer 210 and first strengthening layer 213-1, but notexperienced to any significant degree by second structural layer 215.The second embodiment of the laminate multi-layer design, shown in FIG.4B, is particularly suitable where tensile loads may be experienced byboth the combination of first structural layer 210 and firststrengthening layer 213-1, and also by the combination of secondstructural layer 215 and second strengthening 213-2. Strengthening layer213-1 and/or strengthening layer 213-2 can be omitted in the absence oftensile loading in the applicable region. Further, although the interiorsheathing layer 282 is shown bonded to first structural layer 210, itcan with equal facility be bonded to second structural layer 215, wherethat structural layer faces the interior, inhabited portion of thestructure. Interior sheathing layer 282 can also be omitted where notdesired.

Third Embodiment

A third embodiment of the laminate multi-layer design is shown in FIG.4C. As compared to the second embodiment shown in FIG. 4B, the thirdembodiment of FIG. 4C has a sheet metal layer 205 in lieu of secondstructural layer 215, but is otherwise identical in design to the secondembodiment shown in FIG. 4B. Sheet metal layer 205, which can be steelor aluminum for example, is made from a plurality of generally planarrectangular metal sheets 206 positioned adjacent to each other togenerally cover the full area of the intended enclosure component 155,and joined to each other, such as by riveting or welding. Followingjoining, the joined metal sheets 206 of sheet metal layer 205 arefastened with a suitable adhesive spread to the second opposing face offoam panels 214 (the face of foam panels 214 distal from structurallayer 210).

It is preferred that the seams between adjacent foam panels 214 notoverlay or coincide with the seams in the joined metal sheets 206 ofsheet metal layer 205 in the direction across the thickness of theenclosure component 155. Rather, it is preferred that the seams betweenadjacent foam panels 214 be offset a distance from the seams in thejoined metal sheets 206 of sheet metal layer 205. For example, for foampanels 214 vertically positioned side-by-side and joined metal sheets206 vertically positioned side-by-side, the seams between adjacent foampanels can be positioned at or as near the mid-line (the middle dividingline) of joined metal sheets 206 as design, manufacturing and otherconsiderations permit.

In this third embodiment, the metal sheets 206 of sheet metal layer 205can be made of steel, optionally given a protective and/or decorativesurface treatment, each having for example a thickness in the range ofapproximately 26 to 20 gauge (0.0179 inch (0.454 mm) to 0.0478 inch(1.214 mm)). Use of sheet metal layer 205 provides increased tensilestrength as compared for example to a second structural layer 215comprising structural building panels 216, particularly magnesium oxideboards. At the same time, the laminate multi-layer design shown in FIG.4C exhibits substantial compressive strength in the region of a firststructural layer 210 comprising structural building panels 211,particularly magnesium oxide boards.

Fourth Embodiment

A fourth embodiment of the laminate multi-layer design is shown in FIG.4D. As compared to the third embodiment shown in FIG. 4C, the fourthembodiment of FIG. 4D includes a protective layer 293 interposed betweenfoam panels 214 and sheet metal layer 205, but is otherwise identical indesign to the third embodiment shown in FIG. 4C. Protective layer 293comprises a plurality of generally rectangular protective panels 294arranged adjacent to each other to generally cover the full area of theintended enclosure component 155. The protective panels 294 ofprotective layer 293 can principally comprise a fire-resistant inorganiccomposition, such as magnesium oxide (MgO) or calcium sulfate dihydrate(also known as drywall and marketed for example under the trademarkSheetrock®). Suitable protective panels 294 for protective layer 293 canbe magnesium oxide boards approximately four feet (1.22 m) wide byapproximately eight feet (2.44 m) long.

The protective building panels 294 of protective layer 293 are bonded toboth foam panels 214 and sheet metal layer 205 with a suitable adhesivespread applied between protective layer 293 and the second opposing faceof foam panels 214, and between protective layer 293 and sheet metallayer 205. A suitable thickness for protective building panels 294 ofprotective layer 293, using magnesium oxide boards, can be 0.125 inch(3.18 mm). A principal function of protective layer 293 in the fourthembodiment of the laminated multi-layer construction shown in FIG. 4D isto impart fire resistance.

Enclosure Component Exterior Edge Reinforcement

The exterior edges defining the perimeter of each enclosure component155 can be provided with edge reinforcement, as desired. Exterior edgereinforcement can protect foam panel material that would otherwise beexposed at the exterior edges of enclosure components 155. Exterior edgereinforcement can also serve other functions, as described below.Exterior edge reinforcement can be fabricated from one or more oflaminated strand lumber board, wooden board, C-channel extruded aluminumor steel, or the like, and is generally secured to the exterior edges ofenclosure component 155 with fasteners, such as screw or nail fasteners,and/or adhesive.

Enclosure Component Partitioning

Enclosure components 155 in certain instances are partitioned intoenclosure component portions to facilitate forming a compact shippingmodule 100. In those instances where an enclosure component 155 ispartitioned into enclosure component portions, any exterior edgereinforcement on the exterior edges defining the perimeter of theenclosure component is segmented as necessary between or among theportions.

Enclosure Component Interior Edge Reinforcement

An enclosure component 155 partitioned into enclosure component portionswill have interior edges. There will be two adjacent interior edges foreach adjacent pair of enclosure component portions. Such interior edgescan be provided with interior edge reinforcement. Similar to exterioredge reinforcement, such interior edge reinforcement can protect foampanel material that would otherwise be exposed at the interior edges ofenclosure components 155. Interior edge reinforcement can also serveother functions, as described below. Interior edge reinforcement can befabricated from one or more of laminated strand lumber board, woodenboard, C-channel extruded aluminum or steel, or the like, and isgenerally secured to the interior edges of enclosure component 155 withfasteners, such as screw or nail fasteners, and/or adhesive.

Further design details for finished structure 150, wall component 200,floor component 300, and ceiling component 400 are provided in thesections following.

Wall Component (200)

Typically, a finished structure 150 will utilize four wall components200, with each wall component 200 corresponding to an entire wall ofstructure 150. Wall component 200 has a generally rectangular perimeter.The height and length of wall components 200 can vary in accordance withdesign preference, subject to the dimensional restrictions applicable totransport, described above. In this disclosure, where structure 150 isfashioned with two opposing sides longer than the other two sides (as isthe case with type 1 structure 151), the two wall components 200positioned along first and second longitudinal edges 106 and 116 aresometimes referred to as long wall components, with each beingdenominated 200 a, and the two wall components 200 positioned alongfirst and second transverse edges 108 and 110 are sometimes referred toas short wall components, with each being denominated 200 b. Wherestructure 150 is fashioned with all sides of approximately equal length(as is the case with type 2 structure 152), the four wall components 200are sometimes each denominated 200 s. The basic structure and design ofwall component 200 is the same for both type 1 structure 151 and type 2structure 152, and are applicable to structures 150 generally.

In a particular embodiment of the type 1 structure 151 depicted in FIGS.1A and 2A, long wall component 200 a is approximately thirty-nine feet(11.89 m) in length, and short wall component 200 b is approximately19.5 feet (5.94 m) in length; thus long wall components 200 a positionedalong first and second longitudinal edges 106 and 116 are approximatelytwice the length of short wall components 200 b positioned along firstand second transverse edges 108 and 110. Long wall components 200 a andshort wall components 200 b are approximately 9.5 feet (2.9 m) in heightand approximately six inches (15.24 cm) in thickness.

As indicated above, the type 2 structure 152 shown in FIGS. 1B and 2Bhas wall components 200, 200 s of equal length (each denominated 200s)—i.e., type 2 structure 152 generally has a square shape. Thus in thecase of type 2 structure 152, the first and second longitudinal edges106 and 116, and the first and second transverse edges 108 and 110, areall of equal length. In a particular embodiment of the type 2 structure152 shown in FIGS. 1B and 2B, wall components 200, 200 s can beapproximately 19 feet (5.79 m) in length, approximately 9.45 feet (2.88m) in height and approximately six inches (15.24 cm) in thickness.

As indicated above, wall components 200 of the present inventionspreferably utilize one of the laminate multi-layer designs describedabove in reference to FIGS. 4A-4D. For example, long wall component 200a, shown in FIGS. 5A and 5B, can utilize the second embodiment of thelaminate multi-layer designs described with reference to FIG. 4B. Theparticular embodiment of wall component 200 s of the type 2 structure152 shown in FIGS. 1B and 2B referenced above can utilize the secondmulti-layer design (FIG. 4B) with 0.25 inch (0.635 cm) thick MgO boardfor structural building panels 211 of first structural layer 210 andalso for structural building panels 216 of second structural layer 211,with binding strips 211, 217 of 0.25 inch (0.635 cm) thick MgO board sixinches (15.24 cm) wide. The foam panels 214 can be 5.5 inches (13.97 cm)thick, yielding a wall component 200 approximately six inches (15.24 cm)thick.

The perimeter of each wall component 200 is generally provided withexterior edge reinforcement. As exemplified by long wall component 200 ashown in FIG. 5A, the exterior edge reinforcement for wall component 200is a floor plate 220 along the bottom horizontal edge, a ceiling plate240 along the top horizontal edge and two end pieces 270 respectivelyfastened at each vertical edge 275 of wall component 200. In the case ofa wall component 200, exterior edge reinforcement provides regions forfastening like regions of abutting wall components 200, ceilingcomponent 400 and floor component 300, in addition to in addition toprotecting the exterior edges of foam panel material.

The exterior edge reinforcement for wall component 200 provided by floorplate 220, ceiling plate 240, and end pieces 270 can be fabricated fromone or more of laminated strand lumber board, wooden board, C-channelextruded aluminum or steel, or the like. Alternatively, appropriateenclosure component perimeter structures of a type disclosed in U.S.Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application, can be employedin addition to or in substitution for exterior edge reinforcement of thetype just described for wall component 200. The contents of that U.S.Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application, are incorporatedby reference as if fully set forth herein, particularly including theenclosure component perimeter structures described for example atparagraphs 110-124 and in FIGS. 10-12 thereof. Notably, those enclosurecomponent perimeter structures can also perform a sealing function, toinhibit water ingress and environmental exposure.

Wall Partitioning

Partitioned Wall Portions of Type 1 Structure (151). Referring to FIG.2A, the two short wall components 200 b of type 1 structure 151 eachcomprises first wall portion 200 b-1 and second wall portion 200 b-2.Each of wall portions 200 b-1 and 200 b-2 is a generally rectangularplanar structure. The interior vertical edge 191-1 of each of wallportions 200 b-1 is proximate to a respective interior vertical edge191-2 of wall portion 200 b-2. Interior edge reinforcement can beprovided at any one or more of vertical edges 191-1 and 191-2, examplesof which include laminated strand lumber board, wooden board, C-channelextruded aluminum or steel.

Referring again to FIG. 2A, the two first wall portions 200 b-1 arelocated at fixed positions, opposite each other on floor portion 300 a,proximate first and second transverse edges 108, 110 of finishedstructure 150. Each first wall portion 200 b-1 is joined to a secondwall portion 200 b-2 with a hinge structure. These hinge structurespermit second wall portions 200 b-2 to pivot about vertical axes 191between a folded position and an unfolded position. FIG. 2A depictssecond portions 200 b-2 both in their unfolded positions, where they aredenominated 200 b-2 u, and in their inwardly folded positions, wherethey are denominated 200 b-2 f. When second portions 200 b-2 are intheir folded positions, they facilitate forming a compact shippingmodule. When second portions 200 b-2 are in their unfolded positions,with first portions 200 b-1 they form the short wall components 200 b oftype 1 structure 151 shown in FIG. 2A.

Partitioned Wall Portions of Type 2 Structure (152). Referring to FIG.2B, type 2 structure 152 has two opposing wall components 200 s, whereone of the opposing wall components 200 s comprises first wall portion200 s-1, second wall portion 200 s-2 and third wall portion 200 s-3, andthe other of the opposing wall components 200 s comprises fourth wallportion 200 s-4 and fifth wall portion 200 s-5. Each of wall portions200 s-1, 200 s-2, 200 s-3, 200 s-4 and 200 s-5 has a generallyrectangular planar structure. As shown in FIG. 2B, the interior verticaledge 192-1 of wall portion 200 s-1 is proximate to a respective interiorvertical edge 192-2 of wall portion 200 s-2, and the interior verticaledge 193-2 of wall portion 200 s-2 is proximate a respective interiorvertical wall edge 193-3 of wall portion 200 s-3. Also as shown in FIG.2B, the interior vertical edge 194-4 of wall portion 200 s-4 isproximate to a respective interior vertical edge 194-5 of wall portion200 s-5. Interior edge reinforcement can be provided at any one or moreof vertical edges 192-1, 192-2, 193-2, 193-3, 194-4 and 194-5, examplesof which include laminated strand lumber board, wooden board, C-channelextruded aluminum or steel.

Referring again to FIG. 2B, first wall portion 200 s-1 is fixed inposition on floor portion 300 a proximate to first transverse edge 108,and fourth wall portion 200 s-4 is fixed in position on floor portion300 a, opposite first wall portion 200 s-1 and proximate to secondtransverse edge 110. First wall portion 200 s-1 is joined to second wallportion 200 s-2 with a hinge structure that permits wall portion 200 s-2to pivot about vertical axis 192 between a folded position and anunfolded position. Further, second wall portion 200 s-2 is joined tothird wall portion 200 s-3 with a hinge structure to permit third wallportion 200 s-3 to pivot about vertical axis 193 between a foldedposition and an unfolded position. For the opposing wall, fourth wallportion 200 s-4 is joined to fifth wall portion 200 s-5 with a hingestructure that permits first wall portion 200 s-5 to pivot aboutvertical axis 194 between a folded position and an unfolded position.Notably, fifth wall portion 200 s-5 is longer than either second wallportion 200 s-2 or third wall portion 200 s-3.

FIG. 2B depicts second wall portion 200 s-2 and third wall portion 200s-3 both in their unfolded positions, where they are denominated by 200s-2 u and 200 s 3-u respectively, and depicts fifth wall portion 200 s-5in its unfolded position, where it is denominated 200 s-5 u. FIG. 2Balso depicts second wall portion 200 s-2 and third wall portion 200 s-3both in their inwardly folded positions, where they are denominated by200 s-2 f and 200 s 3-f respectively, and depicts fifth wall portion 200s-5 in its inwardly folded position, where it is denominated 200 s-5 f.When second wall portion 200 s-2, third wall portion 200 s-3 and fifthwall portion 200 s-5 are in their inwardly folded positions, theyfacilitate forming a compact shipping module. When second wall portion200 s-2 and third wall portion 200 s-3 are in their unfolded positions,with first wall portion 200 s-1 they form the wall component 200 sproximate first transverse edge 108. When fifth wall portion 200 s-5 isin its unfolded position, with fourth wall portion 200 s-4 they form thewall component 200 s proximate second transverse edge 110.

The hinge structures described above (for securing each first wallportion 200 b-1 to its second wall portion 200 b-2, first wall portion200 s-1 to second wall portion 200 s-2, second wall portion 200 s-2 tothird wall portion 200 s-3, and fourth wall portion 200 s-4 to fifthwall portion 200 s-5), can be surface mounted or recessed, and of atemporary or permanent nature. The provision of interior edgereinforcement, as described above, can provide a region for securinghinge structures. Suitable hinge structures can be fabricated forexample of metal, plastic, leather, ferrous or non-ferrous material.Alternatively, suitable hinge structures are disclosed in U.S.Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application. The contents ofthat U.S. Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application, are incorporatedby reference as if fully set forth herein, particularly including thehinge structure described for example at paragraphs 147-157 and depictedin FIG. 15 thereof. These hinge structures can be utilized in additionto or in lieu of interior edge reinforcement, as described above, andcan also perform a sealing function, to inhibit water ingress andenvironmental exposure.

Non-Partitioned Wall Components of Type 1 Structure (151). As comparedto the two short wall components 200 b of type 1 structure 151, whichare each partitioned into two portions, the two long wall components 200a shown in FIG. 2A do not comprise plural wall portions, but rather eachis a single piece structure. However, one of these long wall components200 a, which is located on floor portion 300 b proximate to firstlongitudinal edge 106, and which is sometimes denominated as (long) wallcomponent 200 a-P in this disclosure, is pivotally secured to floorportion 300 b to permit wall component 200 a-P to pivot about horizontalaxis 105 shown in FIG. 3A from a folded position to an unfoldedposition. Pivotally securing long wall component 200 a-P alsofacilitates forming a compact shipping module 100. The remaining longwall component 200 a, sometimes denominated 200 a-R in this disclosure,is rigidly secured on floor portion 300 a proximate second longitudinaledge 116 and abutting the vertical edges of the two first wall portions200 b-1 proximate second longitudinal edge 116, as shown in FIG. 2A.

Non-Partitioned Wall Components of Type 2 Structure (152). As comparedto the two wall components 200 s of type 2 structure 152, which are eachpartitioned into portions, the remaining two wall components 200 s shownin FIG. 2B do not comprise plural wall portions, but rather are singlepiece structures. However, one of these wall components 200 s, which issometimes denominated 200 s-P in this disclosure, and which is locatedon floor portion 300 b proximate to first longitudinal edge 106, ispivotally secured to floor portion 300 b to permit wall component 200s-P to pivot about horizontal axis 105 shown in FIG. 3B from a foldedposition to an unfolded position. Pivotally securing wall component 200s-P also facilitates forming a compact shipping module 100. Theremaining wall component 200 s, sometimes denominated 200 s-R in thisdisclosure, is rigidly secured on floor portion 300 a proximate secondlongitudinal edge 116 and abutting the vertical edges of first wallportion 200 s-1 and fourth wall portion 200 s-4 proximate to secondlongitudinal edge 116, as shown in FIG. 2B.

The hinge structures described above, for securing wall component 200a-P to floor portion 300 b, and for securing wall component 200 s-P tofloor portion 300 b, can be surface mounted or recessed, and of atemporary or permanent nature. The provision of exterior edgereinforcement, as described above, can provide a region for securinghinge structures. Suitable hinge structures can be fabricated forexample of metal, plastic, leather, ferrous or non-ferrous material.Alternatively, suitable hinge structures are disclosed in U.S.Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application (with the utilizedhinge structure altered as may be appropriate, given the 90 degree (90°)junction between floor component 300 b and wall component 200 a-P/200s-P when either of the latter is in an unfolded position). The contentsof that U.S. Nonprovisional patent application Ser. No. 16/786,202entitled “Enclosure Component Perimeter Structures,” having the sameinventors and filed on the same date as the subject application, areincorporated by reference as if fully set forth herein, particularlyincluding the hinge structures described for example at paragraphs125-157 and depicted in FIGS. 13A-15 thereof. These hinge structures canbe utilized in addition to or in lieu of exterior edge reinforcement, asdescribed above, and can also perform a sealing function, to inhibitwater ingress and environmental exposure.

Wall Chases

Where wall component 200 utilizes one of the multi-laminate designsdescribed with respect to FIGS. 4A-4C, the foam panels 214 can beprovided with a series of elongate, generally parallel, approximatelyvertically-oriented cylindrical passageways, spaced apart at regularintervals across the entire distance between end pieces 270, with eachspanning the distance between floor plate 220 and ceiling plate 240.These vertical passageways are denominated wall chases 219 and can beseen in FIG. 6A in wall components 200 a, 200 b for a type 1 structure151, and in FIGS. 5C and 7A for a wall component 200 s for a type 2structure 152. Wall chases 219 facilitate the installation of utilitylines (such as for electrical power, lighting control, heating,ventilation, and air conditioning (HVAC), HVAC control, securitysystems, including energizing and communicating with smoke or heatsensors, etc.), in wall component 200. In the embodiment shown in FIG.5C, wall chases 219 are spaced apart for example at uniform intervals ofapproximately twenty-nine inches (73.7 cm).

There optionally can be provided a horizontal passageway located abovefloor plate 220 and intersecting wall chases 219, as show in FIG. 5C.The purpose of this horizontal passageway, denominated connecting wallchase 207, is to facilitate wiring across wall component 200. Connectingwall chase 207 can be located for example approximately 16 inches (40.64cm) above floor plate 220. Although only one horizontal connecting wallchase 207 is shown, one or more additional such wall chases 207 can beprovided in wall component 200, for example at a height suitable forwall switches, to facilitate installation and connection of such wallswitches. As appropriate, segments of connecting wall chase 207 runningacross plural wall portions are aligned to communicate with each otherwhen such portions are deployed.

The vertical and horizontal passageways in foam panels 214 defining wallchases 207 and 219 preferably are formed prior to assembly of foampanels 214 into the laminate multi-layer structure of wall component200. These passages can be formed for example by use of a hot wirepositioned over a select foam panel 214 and oriented parallel along itslength to a surface of the panel 214. The hot wire is then displacedinto the panel foam 214 below the surface of the panel. Once anappropriate depth is reached, the axis of the hot wire is directed in acircular path, so that the length of the wire traces within the foam ofthe panel 214 a cylindrical shape, which results in forming a foam plugsevered from the bulk foam. Removal of the foam plug yields the desiredpassageway defining a wall chase 219 or a connecting wall chase 207.Each chase 207, 219 preferably is provided with a diameter sufficient topermit the installation of utility lines; for example, approximately oneto two inches (2.54 to 5.08 cm) in diameter.

Ceiling plate 240 is provided with a plurality of spaced apartcylindrical through-holes 209, shown in FIGS. 5A, 5B and 5C, which alignwith wall chases 219 to allow communication between the region aboveceiling plate 240 and wall chases 219. Likewise, floor plate 220 isprovided with a plurality of spaced-apart cylindrical through-holes 291,shown in FIG. 5C, which align with wall chases 219 to allowcommunication between the region below floor plate 220 and wall chases219. In the event that wall component 200 is provided with enclosurecomponent perimeter structures, of a type described in U.S.Nonprovisional patent application Ser. No. 16/786,202 entitled“Enclosure Component Perimeter Structures,” having the same inventorsand filed on the same date as the subject application, either bondedover or in place of either or both of floor plate 220 and ceiling plate240, then those structures can be provided with suitable apertures atcomparable locations to through-holes 209 and 291 to permitcommunication to the wall chases 219.

Wall chases 219 communicate with a utility service system 460 located inceiling component 400, as described below.

Wall Customization Options

FIGS. 1A and 2A depicts wall components 200 having plural apertures,specifically door apertures 202, for receiving door frame and doorassemblies, and window apertures 204, for receiving window frame andwindow assemblies. A feature of the present inventions is that themulti-laminate construction of wall component 200 lends itself to a highdegree of customization in terms of type, size and location of doors,windows and the like, while the number of apertures 202, 204 can bevaried in accordance with design preference.

For example, once erected at the intended location for the structure,the builder can cut door and window apertures 202, 204 in wallcomponents 200 (as shown in FIG. 1A), in accordance with the purchaser'sdesign choices. Window and door assemblies of any number, size and shapecan thus be placed virtually anywhere, limited only by retaining enoughwall laminate to insure the structural integrity of wall component 200in the face of such vertical and shear loads as may arise from normaluse and during transient events (such as storms and seismic activity).The monocoque laminate multi-layer structure of wall component 200supports loads across its length and thus confers a great degree ofdesign freedom, and without the need for adding on-site anyload-distributing lintels or headers.

After apertures are cut to the appropriate size and shape, windowassemblies and door assemblies can then be inserted and secured to wallcomponent 200 with adhesive or by other suitable means. A wide varietyof window and door assemblies are commercially available and suitablefor use with the present inventions. As a non-limiting example, a doorassembly can include all components for mounting the door and renderingit operative, such as two side jambs, a head jamb and a sill, togetherwith a door hinged to one of the side jambs. Likewise as a non-limitingexample, a window assembly can include all components for mounting thewindow and rendering it operative, such as a sill, side jambs, headjambs, window frames and glass, sash pulleys and the like.

Ceiling Component (400)

Typically, a finished structure 150 will utilize one ceiling component400; thus ceiling component 400 generally is the full ceiling offinished structure 150. Ceiling component 400 has a generallyrectangular perimeter. Among others, FIGS. 6A-7B depict ceilingcomponent 400 in accordance with the present inventions. The perimeterof ceiling component 400 is defined by first longitudinal ceiling edge406, first transverse ceiling edge 408, second longitudinal ceiling edge416 and second transverse ceiling edge 410. In particular, (a) firstlongitudinal ceiling edge 406, (b) first transverse ceiling edge 408,(c) second longitudinal ceiling edge 416 and (d) second transverseceiling edge 410 of ceiling component 400 generally coincide with (i.e.,overlie) (w) first longitudinal edge 106, (x) first transverse edge 108,(y) second longitudinal edge 116 and (z) second transverse edge 110,respectively, of finished structure 150. FIGS. 6A and 6B depict theceiling component 400 of a type 1 structure 151, and FIGS. 7A and 7Bdepict the ceiling component 400 of a type 2 structure 152. The basicstructure and design of ceiling component 400 is the same for both type1 structure 151 and type 2 structure 152, and are applicable tostructures 150 generally, and is generally applicable to ceilingcomponents 400 of structures 150 fabricated in accordance with thisdisclosure.

The length and width of ceiling component 400 can vary in accordancewith design preference. In a particular embodiment of the type 1structure 151 depicted in FIGS. 1A and 2A, ceiling component 400 (thedimension along first and second longitudinal edges 106, 116) isapproximately thirty-nine feet (11.89 m) in length (the dimension alongfirst and second longitudinal ceiling edges 406, 416) and approximately19.5 feet (5.94 m) in width (the dimension along first and secondtransverse ceiling edges 408, 410). In a particular embodiment of thetype 2 structure 152 depicted in FIGS. 1B and 2B, ceiling component 400is approximately 19 feet (5.79 m) square.

It is preferred that ceiling component 400 utilize one of themulti-laminate designs described above in regard to FIGS. 4A-4D, asdescribed below.

The perimeter of ceiling component 400 is generally provided withexterior edge reinforcement. As exterior edge reinforcement for theembodiments of ceiling component 400 shown for a type 1 structure 151 inFIG. 6B and for a type 2 structure 152 in FIG. 7A, a first shoulder beam435 is positioned at the first longitudinal ceiling edge 406 of ceilingcomponent 400, a second shoulder beam 435 (visible edge-on in FIG. 7B)is positioned at the second transverse ceiling edge 408 of ceilingcomponent 400, a third shoulder beam 435 (visible edge-on in FIG. 7B) ispositioned at the first transverse exterior ceiling edge 410 of ceilingcomponent 400, and a fourth shoulder beam 435 is positioned at thesecond longitudinal ceiling edge 416 of ceiling component 400 (see FIG.6B). In the case floor component 400, in addition to protecting theexterior edges of foam panel material, the exterior edge reinforcementprovided by shoulder beams 435 assists in resisting vertical loads andtransferring such loads to lower floors through underlying wallcomponents 200 supporting ceiling component 400, and then to thefoundation of the finished structure 150. Such exterior edgereinforcement can also provide a region for fastening like regions ofabutting enclosure components 155 (underlying and any overlying).

The exterior edge reinforcement provided by shoulder beams 435 ofceiling component 400 can be fabricated from one or more of laminatedstrand lumber board, wooden board, C-channel extruded aluminum or steel,or the like. Alternatively, appropriate enclosure component perimeterstructures of a type disclosed in U.S. Nonprovisional patent applicationSer. No. 16/786,202 entitled “Enclosure Component Perimeter Structures,”having the same inventors and filed on the same date as the subjectapplication, can be employed in addition to or in substitution forexterior edge reinforcement of the type just described for ceilingcomponent 400. The contents of that U.S. Nonprovisional patentapplication Ser. No. 16/786,202 entitled “Enclosure Component PerimeterStructures,” having the same inventors and filed on the same date as thesubject application, are incorporated by reference as if fully set forthherein, particularly including the enclosure component perimeterstructures described for example at paragraphs 110-124 and in FIGS.10-12 thereof. Notably, those enclosure component perimeter structurescan also perform a sealing function, to inhibit water ingress andenvironmental exposure.

Ceiling Partitioning

The type 1 structure 151 and the type 2 structure 152 each includesceiling portions 400 a, 400 b and 400 c. Each of the ceiling portions400 a, 400 b and 400 c is a planar generally rectangular structure, withceiling portion 400 a adjoining ceiling portion 400 b, and ceilingportion 400 b adjoining ceiling portion 400 c as exemplified by FIGS. 6Aand 6B.

Ceiling Portion 400 c. Ceiling portion 400 c is generally exemplary ofthe construction of all ceiling portions 400 a, 400 b and 400 c.Referring to the segment of ceiling portion 400 c depicted in FIG. 6C,ceiling portion 400 c utilizes a laminated multi-layer design accordingto the first embodiment thereof (depicted in FIG. 4A) or the secondembodiment thereof (depicted in FIG. 4B). As relevant here, ceilingportion 400 c includes a first structural layer 210 of structuralbuilding panels 211, denominated ceiling bottom surface 404, and asecond structural layer 215 of structural building panels 216,denominated ceiling top surface 402. Between ceiling surfaces 402 and404 there are foam panels 214, denominated ceiling foam panels 414.Interior edge 412 c of ceiling component 400 c abuts a first interioredge 412 b of ceiling component 400 b, as shown in FIGS. 6B and 7A. Forinterior edge reinforcement, a reinforcing board 437 is positionedadjacent interior edge 412 c.

Ceiling Portion 400 a. Ceiling portion 400 a is shown for example inFIGS. 6B, 6D and 7A. It is a mirror image in design and construction ofceiling portion 400 c. Interior edge 412 a of ceiling portion 400 aabuts a second interior edge 412 b of ceiling portion 400 b, as shown inFIGS. 6B and 7A. For interior edge reinforcement, a reinforcing board437 is positioned adjacent interior edge 412 a.

Ceiling Portion 400 b. Ceiling portion 400 b shown in FIGS. 6B and 7A isthe same in general design and construction as ceiling portions 400 aand 400 c. First interior edge 412 b of ceiling component 400 b abutsinterior edge 412 c of ceiling component 400 c, and second interior edge412 b of ceiling component 400 b abuts interior edge 412 a of ceilingportion 400 a. For interior edge reinforcement, a reinforcing board 437is positioned adjacent first interior edge 412 b of ceiling portion 400b, and a reinforcing board 437 is positioned adjacent second interioredge 412 b of ceiling portion 400 b.

Ceiling component 400 and its constituent elements are generallydimensioned in thickness and otherwise to accommodate the particularloads to which ceiling component 400 may be subject. A particularembodiment of ceiling component 400 in the type 2 structure 152 shownfor example in FIGS. 7A and 7B can utilize the second multi-layer designembodiment (see FIG. 4B) with 0.25 inch (0.635 cm) thick MgO board forstructural building panels 211 of first structural layer 210/ceilingbottom surface 404 and also for structural building panels 216 of secondstructural layer 211/ceiling top surface 402, and with binding strips of0.25 inch (0.635 cm) thick MgO board six inches (15.24 cm) wide. Thefoam panels 214/ceiling foam panels 414 can be 7.9 inches (20.07 cm)thick, yielding a roof component 400 approximately 8.4 inches (21.34 cm)thick. Additional structural members, such as joists 420 (a portion of ajoist 420 is visible in FIG. 6D), can be utilized as is appropriate tothe specific design of structure 150 to assist in the transfer ofvertical loads to one or more shoulder beams 435.

Referring to the type 1 structure 151 shown in FIG. 6B, ceiling portion400 a is fixed in position relative to first portions 200 b-1 of shortwall components 200 b and relative to long wall component 200 a-R, andis joined with hinge structures along longitudinal interior edge 412 ato the abutting longitudinal interior edge 412 b of ceiling portion 400b. Such hinge structures are adapted to permit ceiling portion 400 b topivot through up to one hundred and eighty degrees (180°) of arc about ahorizontal axis 405 a, located proximate the top of ceiling component400, between a folded position, where ceiling portion 400 b lies flatagainst ceiling portion 400 a, and the fully unfolded position shown inFIG. 6B.

In turn, ceiling portion 400 b is joined with hinge structures toceiling portion 400 c at the longitudinal interior edge 412 b of ceilingportion 400 b abutting the longitudinal interior edge 412 c of ceilingportion 400 c. Such hinge structures are adapted to permit ceilingportion 400 c to pivot through up to one hundred and eighty degrees(180°) of arc about a horizontal axis, located proximate the bottom ofceiling component 400, between a folded position, where ceiling portion400 c lies flat against ceiling portion 400 b (when ceiling portion 400b is positioned to lie flat against ceiling portion 400 a), and thefully unfolded position shown in FIG. 6B.

Likewise referring to the type 2 structure 152 shown in FIG. 7A, ceilingportion 400 a is fixed in position relative to first wall portion 200s-1, fourth wall portion 200 s-4 and wall component 200 s-R. Ceilingportions 400 a, 400 b and 400 c for type 2 structure 152 are joined withhinge structures in the same manner as described above in connectionwith type 1 structure 151.

The hinge structures joining ceiling portions 400 a, 400 b and 400 c canbe surface mounted or recessed, and of a temporary or permanent nature.Suitable hinge structures can be fabricated for example of metal,plastic, leather, ferrous or non-ferrous material. The interior edgereinforcement provided by reinforcing boards 437 of ceiling portions 400a, 400 b and 400 c provides structure for mounting hinge structures, inaddition to protecting the edges of foam panel material. Reinforcingboards 437 can be fabricated for example from one or more of laminatedstrand lumber board, wooden board, C-channel extruded aluminum or steel,or the like.

A suitable hinge structure and its associated members is shown in FIG. 9, which depicts an exemplary hinge structure joining ceiling portions400 b and 400 c. In particular, a plurality of double hinges 413 arearranged in line along horizontal axis 405 b. Double hinges arepreferred to permit the hinges to be recessed below the surface, whileretaining the ability to pivot through up to one hundred eighty degrees(180°) of arc, without causing interference crimping between adjacentceiling portions. These double hinges can be fabricated by positioningtogether in an abutting relationship two single hinges, each along oneof their respective leaves, and welding them to fashion one double hinge413.

As shown in FIG. 9 , each of the free leaves of double hinge 413 arerespectively secured to a reinforcing board 437. Each reinforcing board437 is positioned against the exterior of the web of a C-channel track308 (fabricated from cold formed steel), each of which in turn issecured to the respective abutting edges of roof portions 400 b and 400c, as shown in FIG. 9 . The same hinge structure can be utilized tosecure together ceiling portions 400 a and 400 b, although rotated 180degrees and displaced to be arranged in line along horizontal axis 405a, so as to permit the ceiling portions 400 b and 400 c to fold in anaccordion pattern, as shown in FIGS. 3A and 3B.

As further alternatives to the hinge structure depicted in FIG. 9 ,suitable hinge structures are disclosed in U.S. Nonprovisional patentapplication Ser. No. 16/786,202 entitled “Enclosure Component PerimeterStructures,” having the same inventors and filed on the same date as thesubject application. The contents of that U.S. Nonprovisional patentapplication Ser. No. 16/786,202 entitled “Enclosure Component PerimeterStructures,” having the same inventors and filed on the same date as thesubject application, are incorporated by reference as if fully set forthherein, particularly including the hinge structures described forexample at paragraphs 125-157 and depicted in FIGS. 13A-15 thereof, andmore particularly the hinged structure described at paragraphs 136-146and depicted in FIGS. 14A-14F. These hinge structures can be employed inaddition to or in substitution for the interior edge reinforcementprovided by reinforcing boards 437 of ceiling portions 400 a, 400 b and400 c, and can also perform a sealing function, to inhibit water ingressand environmental exposure.

Ceiling Chases

Each of ceiling portions 400 a, 400 b and 400 c can be provided withceiling chases. As described below, the ceiling chases 219 communicatewith utility service system 460 and wall chases 219.

FIG. 7D is a plan view of ceiling 400 of type 2 structure 152 sectionedto reveal a particular embodiment of a ceiling chase configuration.While shown for a type 2 structure 152, ceiling chases 219 can also beutilized in a type 1 structure 151, or in any other structure 150fabricated in accordance with this disclosure.

As shown in FIG. 7D, there is provided a first plurality of elongatecylindrical passages, ceiling chases 440, spaced apart at regularintervals across the entire distance between first and second transverseceiling edges 408 and 410, and arranged in a first direction generallyparallel to first and second transverse ceiling edges 408 and 410 and toeach other. Each of such ceiling chases 440 spans the distance betweenthe shoulder beams 435 located proximate to first and secondlongitudinal ceiling edges 406 and 416, respectively. There is alsoprovided a second plurality of ceiling chases 440, spaced apart atregular intervals across the entire distance between first and secondlongitudinal edges 406 and 416, and arranged in a second directionapproximately perpendicular to the first direction and generallyparallel to first and second longitudinal ceiling edges 406 and 416 andto each other. Each of such ceiling chases 440 spans the distancebetween the shoulder beams 435 located proximate to first and secondtransverse ceiling edges 408 and 410, respectively. The first and secondplurality of spaced-apart ceiling chases accordingly form a ceilingchase grid. The provision of ceiling chases 440 facilitates routing ofutility lines (such as for electrical power, lighting control, HVAC,HVAC control, security systems, including energizing and communicatingwith smoke or heat sensors, etc.) to locations on ceiling component 400distal from a wall component 200. As shown, the ceiling chase segmentsin ceiling portions 400 a, 400 b and 400 c are aligned to communicatewhen ceiling portions 400 b and 400 c are deployed to form a completeceiling component 400.

Each ceiling chase 219 preferably is provided with a diameter sufficientto permit the installation of utility lines; for example, approximatelyone to two inches (2.54 to 5.08 cm) in diameter. Ceiling chases 219 canbe formed in ceiling foam panels 414 by use of a circular hot wireappropriately positioned and displaced into the foam panels below thesurfaces of the panels, generally in the same manner described above toform wall chases 207 and 219.

Ceiling chases 219 communicate with utility service system 460 locatedin ceiling component 400, described below.

Utility Service System (460)

As shown in FIGS. 6A-7E, there are provided two embodiments of a utilityservice system 460 in ceiling component 400.

The purpose of utility service system 460 is to provide a recessedpassageway in finished structure 150 through which utility lines can beconveniently routed and connected. In general terms, utility servicesystem 460 comprises one or more passageways, preferably of closed loopform, located about the entirety of the periphery of ceiling component400; i.e., approximately adjacent or proximate to the first and secondlongitudinal exterior ceiling edges 406 and 416, and approximatelyadjacent or proximate to the first and second transverse ceiling edges408 and 410, of ceiling component 400. Thus the structure definingutility service system 460 is provided in each of ceiling portions 400a, 400 b and 400 c generally proximate to the shoulder beams 435included in those ceiling portions.

Utility service system 460 is adapted to contain utility lines (such asfor electrical power, lighting control, HVAC, HVAC control, securitysystems, including energizing and communicating with smoke or heatsensors, etc.). As shown, the segments of utility service system 460 inceiling portions 400 a, 400 b and 400 c are aligned to communicate witheach other when the ceiling portions are deployed to form a completeceiling component 400. In the event that there are used in any ofceiling portions 400 a, 400 b and 400 c structural members such asjoists 420 (as mentioned previously, a portion of a joist 420 is visiblein FIG. 6D), and/or interior edge reinforcement (such as reinforcingboards 437), there can be provided passage holes 422 (visible in FIG.6D) in the portions spanning utility service system 460 to facilitatefree routing of utility lines through those joists and/or reinforcingboards 437 and about the entire circumference of utility service system460.

The two embodiments for utility service system 460 described herein arebuilt-up utility channel 461 and in situ utility conduits 471. Whilebuilt-up utility channel 461 is depicted in a type 1 structure 151, andin situ utility conduits 471 are depicted in a type 2 structure 152,either of these utility systems 460 can be utilized in the other type ofstructure as well, or in any other structure fabricated in accordancewith this disclosure.

Built-up Utility Channel (461)

As shown in FIGS. 6A-6E, built-up utility channel 461 is a three-sidedcavity, formed in the underside of ceiling component 400, and having anexterior edge, an interior edge and a top. As indicated above, built-uputility channel 461 preferably forms a closed loop, located about theentirety of the periphery of ceiling component 400.

Referring particularly to FIG. 6C, the exterior edge of built-up utilitychannel 461 is defined by shoulder beam 435, the interior edge ofchannel 461 is defined by channel closure board 467 and the top ofutility channel 461 is defined by channel top surface 462. Channelclosure board 467 can be made for example from one or more of laminatedstrand lumber board, wooden board, C-channel extruded aluminum or steel,or the like, and channel top surface 462 can be made for example ofmagnesium oxide board having a thickness of approximately 0.5 inch (1.27cm). It is preferred that the width of built-up utility channel 461 besufficient to allow reasonable access for construction and servicepersonnel.

At regular spaced-apart intervals along the inner face of each shoulderbeam 435 in ceiling portions 400 a, 400 b and 400 c, there are provideda first set of plural apertures, denominated horizontal channelconnectors 438. Horizontal channel connectors 438 can either passentirely through shoulder beam 435, or alternatively and preferably,terminate within shoulder beam 435 (as shown in FIG. 6C) to create acavity in shoulder beam 435. As shown in FIG. 6C, there is additionallyprovided at spaced-apart intervals along the bottom face of eachshoulder beam 435 a second set of plural apertures, denominated verticalchannel connectors 439. Each vertical channel connector 439 opens intoand communicates with a respective horizontal channel connector 438 toprovide a passage through shoulder beam 435 from below its bottom faceand out its inner face.

Vertical channel connectors 439 are positioned so as to align withthrough-holes 209 in the wall component 200 supporting the shoulder beam435, so as to provide a passageway for routing utility lines from withinutility channel 461 into wall chases 219 of wall component 200, and, asdesired, further into floor chases 319 of floor component 300, describedbelow. The horizontal channel connectors 438, the vertical channelconnectors 439, the through-holes 209 and the wall chases 219 all can bespaced apart at uniform intervals, for example at approximatelytwenty-nine inch (73.7 cm) intervals.

Built-up utility channel 461 can be provided with pluralserially-abutting removable channel cover plates 464, shown in FIG. 6E,which preferably cover the entirety of built-up utility channel 461.Channel cover plates 464 conceal the utility lines contained therein,and can optionally include lighting accents to enhance the interiorspace, such as the multiple light sources 466 that are shown in FIG. 6E.

In Situ Utility Channels (471)

Utility service system 460 can also be formed in ceiling foam panels 414in situ, as shown in FIGS. 7A-7E. Referring to FIG. 7A for example,there is shown in cross-section ceiling component 400 containing aplurality of ceiling foam panels 414 a. As indicated in that figure,there are provided two in situ utility channels 471 in foam panel 414 a,each of which is substantially circular in cross-section to define twoclosed-loop generally parallel cylindrical passageways which are locatedabout the entirety of the periphery of ceiling component 400 proximatethe shoulder beams 435 in ceiling component 400.

Utility channels 471 each can be formed by use of a circular hot wireappropriately positioned and displaced into the foam panels 414 a belowthe surfaces of the panels, generally in the same manner described abovein regard to the connecting and vertical wall chases 207 and 219. Eachutility channel 471 should have a diameter sufficient to permit theinstallation of utility lines; for example, approximately four inches(10.16 cm) in diameter.

As exemplified by FIG. 7C, each ceiling chase 440 passes through all orsubstantially all of the entirety of ceiling component 400 between twoopposing shoulder beams 435. Each ceiling chase 440 communicates witheach of the two utility channels 471 at two points (one on each side ofceiling component 400 proximate those shoulder beams 435), therebyproviding utility routing access between each ceiling chase 440 andutility channels 471. Proximate the periphery of ceiling component 400,each ceiling chase 440 intersects and communicates with avertically-oriented cylindrical passage, ceiling chase connector 472,which in turn communicates with a respective wall chase 219 through athrough-hole 209 in ceiling plate 240 of wall component 200. Although asdepicted in FIG. 7C each ceiling chase connector 472 abuts, but isformed (in foam panels 414) outside the material of a shoulder beam 435,it can also be located within the material of shoulder beam 435, in themanner of horizontal and vertical channel connectors 438, 439 shown forexample in FIGS. 6C and 6D, as required or as desired. The foregoingarrangement thus provides each utility channel 471 with utility routingaccess to the wall chases 219.

As shown in FIGS. 7C-7E, there is provided a plurality of channel accessapertures 473 proximate the intersection of each ceiling chase 440 andutility channels 471, for service access to the utility channels 471. Itis preferred that the dimensions of channel access apertures 473 besufficient to allow reasonable access for construction and servicepersonnel; for example, each channel access aperture 473 can have arectangular configuration, approximately 14.5 inches (36.8 cm) wide by8.0 inches (20.3 cm) long. Each channel access aperture 473 can becovered by a removable channel access plate 474, shown in FIG. 7E.

Utility Service System Use

As an example of the utility lines that can be installed in utilityservice system 460, FIG. 6E depicts in schematic form a two-wireelectrical loop 208 installed in built-up utility channel 461, and FIG.6A depicts four pre-selected wall chases 219 a, 219 b, 219 c and 219 din the wall components 200 of finished structure 150. One or morecutouts 276 are formed to communicate with wall chases 219 a-d, junctionboxes are placed in the cutouts 276 as appropriate and the chases arewired and connected to loop 208. Apertures for electrical outlets,switches, lighting and the like can be cut into and through interiorsheathing layer 282, first structural layer 210, first woven fiber layer213-1, and into foam panel 214 to form the cut-outs 276 to wall chases219. In a comparable manner, like apertures for cut-outs can be formedin ceiling component 400 to communicate with ceiling chases 219. Thisarrangement provides access to electrical service at a great number ofpoints across wall components 200 and ceiling component 400. The wiringand connection operations are performed preferably following deliveryand deployment of structure 150, whereas the other described operationscan be performed either before or after delivery, as is preferred.

Floor Component (300)

Typically, a finished structure 150 will utilize one floor component300; thus floor component 300 generally is the full floor of finishedstructure 150. Floor component 300 has a generally rectangularperimeter. FIGS. 6A-6B and 7A-7B depict floor component 300 inaccordance with the present inventions. The perimeter of floor component300 is defined by first longitudinal floor edge 117, first transversefloor edge 120, second longitudinal floor edge 119 and second transversefloor edge 118. In particular, (a) first longitudinal floor edge 117,(b) first transverse floor edge 120, (c) second longitudinal floor edge119 and (d) second transverse floor edge 118 generally coincide with(i.e., underlie) (w) first longitudinal edge 106, (x) first transverseedge 108, (y) second longitudinal edge 116 and (z) second transverseedge 110, respectively, of finished structure 150. FIGS. 6A and 6Bdepict the floor component 300 for a type 1 structure 151, and FIGS. 7Aand 7B depict the floor component 300 for a type 2 structure 152. Thebasic structure of floor component 300 is the same for both type 1structure 151 and type 2 structure 152, and is generally applicable tofloor components 300 of structures 150 fabricated in accordance withthis disclosure.

The length and width of floor component 300 can vary in accordance withdesign preference. In the particular embodiment of the type 1 structure151 depicted in FIGS. 1A and 2A, where wall components 200 a, 200 b arevertically oriented, the length and width of ceiling component 400approximates the length and width of ceiling component 400 for that type1 structure. Likewise in the particular embodiment of the type 2structure 152 depicted in FIGS. 1B and 2B, where wall components 200 sare vertically oriented, the length and width of ceiling component 400approximates the length and width of ceiling component 400 for that type2 structure.

It is preferred that floor component 300 utilize one of themulti-laminate designs described above in regard to FIGS. 4A-4D, asdescribed below.

The perimeter of each floor component 300 is generally provided withexterior edge reinforcement. As exterior edge reinforcement for theembodiments of floor component 300 shown in FIGS. 7A and 7B, a firstfooting beam 320 (visible edge-on in FIG. 7A) is positioned at the firstlongitudinal floor edge 117 of floor component 300, a second footingbeam 320 (visible edge-on in FIG. 7B) is positioned at the secondtransverse floor edge 118 of floor component 300, a third footing beam320 (visible edge-on in FIG. 7B) is positioned at the first transversefloor edge 120 of floor component 300, and a fourth footing beam 320 ispositioned at the second longitudinal floor edge 119 of floor component300 (visible edge-on in FIG. 7A). In the case floor component 300, theedge reinforcement provided by footing beams 320 assists in resistingvertical loads and transferring such loads to any ceiling component 400thereunder and then to underlying wall components 200, and/or to thefoundation of the finished structure 150, in addition to protecting theedges of foam panel material.

The exterior edge reinforcement provided by footing beams 420 of floorcomponent 300 can be fabricated from one or more of laminated strandlumber board, wooden board, C-channel extruded aluminum or steel or thelike. Alternatively, appropriate enclosure component perimeterstructures of a type disclosed in U.S. Nonprovisional patent applicationSer. No. 16/786,202 entitled “Enclosure Component Perimeter Structures,”having the same inventors and filed on the same date as the subjectapplication, can be employed in addition to or in substitution forexterior edge reinforcement of the type just described for floorcomponent 300. The contents of that U.S. Nonprovisional patentapplication Ser. No. 16/786,202 entitled “Enclosure Component PerimeterStructures,” having the same inventors and filed on the same date as thesubject application, are incorporated by reference as if fully set forthherein, particularly including the enclosure component perimeterstructures described for example at paragraphs 110-124 and in FIGS.10-12 thereof. Notably, those enclosure component perimeter structurescan also perform a sealing function, to inhibit water ingress andenvironmental exposure.

Floor Partitioning

The floor component 300 in type 1 structure 151 and in type 2 structure152 comprises floor portion 300 a and floor portion 300 b. Each of thefloor portions 300 a and 300 b is a planar generally rectangularstructure, with floor portion 300 a adjoining floor portion 300 b, asexemplified by FIGS. 6A, 6B and 7A.

Floor Portion 300 a. Floor portion 300 a, shown in FIGS. 6A, 6B and 7A,is generally exemplary of the construction of floor portions 300 a and300 b, and as depicted generally utilizes a laminate multi-layer designin accordance with the first or second embodiment thereof respectivelyillustrated in FIGS. 4A and 4B. As relevant here, floor portion 300 aincludes a first structural layer 210 of structural building panels 211,denominated floor bottom surface 304 and a second structural layer 215of structural building panels 216, denominated floor top surface 302.Between floor surfaces 302 and 304 there are foam panels 214,denominated floor foam panels 314. Interior edge 301 a of floor portion300 a abuts interior edge 301 b of floor portion 300 b, as shown in FIG.7A. As interior edge reinforcement, a reinforcing board 307 ispositioned adjacent interior edge 301 a.

Floor Portion 300 b. Floor portion 300 b is shown for example in FIGS.6A, 6B and 7A. It is the same in general design and construction asfloor portion 300 a. Interior edge 301 b of floor portion 300 b abutsinterior edge 301 a of floor portion 300 a, as shown in FIG. 7A. Asinterior edge reinforcement, a reinforcing board 307 is positionedadjacent interior edge 301 b.

Floor component 300 and its constituent elements are generallydimensioned in thickness and otherwise to accommodate the particularloads to which floor component 300 may be subject. A particularembodiment of floor component 300 for the type 2 structure 152 shown forexample in FIGS. 7A and 7B can utilize the second multi-layer designembodiment (see FIG. 4B) with 0.25 inch (0.635 cm) thick MgO board forstructural building panels 211 of first structural layer 210/floorbottom surface 304, and 0.5 inch (1.27 cm) thick MgO board forstructural building panels 216 of second structural layer 211/floor topsurface 302. Correspondingly in this particular embodiment, bindingstrips of 0.25 inch (0.635 cm) thick MgO board six inches (15.24 cm)wide are used to join together the structural building panels 211 offirst structural layer 210/floor bottom surface 304, and binding stripsof 0.5 inch (1.27 cm) thick MgO board six inches (15.24 cm) wide areused to join together the structural building panels 216 of secondstructural layer 211/floor top surface 302. The foam panels 214/floorfoam panels 314 can be 11.25 inches (28.575 cm) thick, yielding a floorcomponent 300 approximately 12 inches (30.48 cm) thick.

The floor portion 300 b comprising floor component 300 can be folded tofacilitate forming a compact shipping module. The type 1 structure 151and the type 2 structure 152 each includes such a floor portion.

Referring to the type 1 structure 151 shown in FIG. 6B, floor portion300 a is fixed in position relative to first wall portions 200 b-1 ofshort wall components 200 b and relative to long wall component 200 a-R,and is joined with hinge structures to floor portion 300 b, so as topermit floor portion 300 b to pivot through approximately ninety degrees(90°) of arc about a horizontal axis 305, located proximate floor topsurface 302, between a folded position, where floor portion 300 b isapproximately vertically oriented as shown in FIG. 3A, and the fullyunfolded position shown in FIGS. 6A and 6B.

Likewise referring to the type 2 structure 152 shown in FIG. 7A, floorportion 300 a is fixed in position relative to first wall portion 200s-1, fourth wall portion 200 s-4 and wall component 200 s-R. Floorportion 300 a is joined with hinge structures to floor portion 300 b inthe same manner as described above in connection with type 1 structure151.

The hinge structures joining floor portions 300 a and 300 b can besurface mounted or recessed, and of a temporary or permanent nature.Suitable hinge structures can be fabricated for example of metal,plastic, leather, ferrous or non-ferrous material. An example of asuitable hinge structure and its associated members is shown in FIG. 8 .In particular, a plurality of steel hinges 306, for exampleapproximately three inches (7.62 cm) wide by approximately six inches(15.24 cm) long, are arranged in line along horizontal axis 305, asshown edge-on in FIG. 8 . Such hinges are commercially available fromMcMaster-Carr, Douglasville, Ga. USA. The hinge structures joining floorportions 300 a and 300 b need not be double hinges, since they need topivot only through approximately ninety degrees (90°) of arc, and thusthe potential for interference crimping is less than in connection withthe ceiling portions of ceiling component 400.

As shown in FIG. 8 , the opposing leaves of hinges 306 are respectivelysecured to the interior edge reinforcement, reinforcing board 307,provided at each of interior edges 301 a and 301 b. Reinforcing boards307 in FIG. 8 are made of laminated strand lumber. Each reinforcingboard 307 is positioned against the exterior of the web of a C-channeltrack 308 (fabricated from cold formed steel), each of which in turn issecured to the respective abutting edges of floor portions 200 a and 200b, as shown in FIG. 8 .

Alternatively, suitable hinge structures for joining floor portions 300a and 300 b are disclosed in U.S. Nonprovisional patent application Ser.No. 16/786,202 entitled “Enclosure Component Perimeter Structures,”having the same inventors and filed on the same date as the subjectapplication. The contents of that U.S. Nonprovisional patent applicationSer. No. 16/786,202 entitled “Enclosure Component Perimeter Structures,”having the same inventors and filed on the same date as the subjectapplication, are incorporated by reference as if fully set forth herein,particularly including the hinge structures described for example atparagraphs 125-157 and depicted in FIGS. 13A-15 thereof, and moreparticularly the hinged structure described at paragraphs 125-135 anddepicted in FIGS. 13A-F. These hinge structures can be utilized inaddition to or in place of interior edge reinforcement, as describedabove, and can also perform a sealing function to inhibit water ingressand environmental exposure.

Baseboard and Perimeter Board

The exterior edges of floor component 300, or portions thereof, such asthe exterior edge of floor portion 300 b located along firstlongitudinal edge 106 of finished structure 150, can be provided with abaseboard 310. In the type 1 structure 151 shown for example in FIG. 3A,a baseboard 310 is shown edge-on secured to the exterior edge of floorportion 300 b. Where baseboard 310 extends around the perimeter of floorcomponent 300, it is termed perimeter board 312. The type 2 structure152 shown for example in FIGS. 1B and 3B utilizes a perimeter board 312.It is preferred that the vertical dimension (height) of baseboard 310(including perimeter board 312) be greater than the thickness of floorcomponent 300.

Floor Chases

Optionally, the floor foam panels 314 in floor component 300 can beprovided with floor chases 319.

FIG. 7F provides a floor component 300 sectioned to reveal an exemplaryfloor chase arrangement. While shown in FIG. 7F for the floor component300 of type 2 structure 152, floor chases 319 can also be utilized inthe floor component 300 of a type 1 structure 151, or in the floorcomponent 300 of any other structure 150 fabricated in accordance withthis disclosure.

As shown in FIG. 7F, there is provided a first plurality of elongatecylindrical passages, floor chases 319, spaced apart at regularintervals across the entire distance between first and second transversefloor edges 120 and 118, and arranged in a first direction generallyparallel to first and second transverse floor edges 120 and 118 and toeach other. Each of such floor chases 319 spans the distance between thefooting beams 320 located proximate to first and second longitudinalfloor edges 117 and 119, respectively. There is also provided a secondplurality of floor chases 319, spaced apart at regular intervals acrossthe entire distance between first and second longitudinal floor edges117 and 119, and arranged in a second direction approximatelyperpendicular to the first direction and generally parallel to first andsecond longitudinal floor edges 117 and 119 and to each other. Each ofsuch floor chases 319 spans the distance between the footing beams 320located proximate to first and second transverse floor edges 120 and118, respectively. The first and second plurality of spaced-apart floorchases 319 accordingly form a floor chase grid. The provision of floorchases 319 facilitates routing of utility lines (such as for electricalpower, lighting control, HVAC, HVAC control, security systems, etc.) tolocations on floor component 300 distal from a wall component 200. Thefloor chase segments in the two floor portions of floor component 300are aligned to communicate when floor portions 300 a and 300 b are fullydeployed to form a complete floor component 300.

Each floor chase 319 preferably is provided with a diameter sufficientto permit the installation of utility lines; for example, approximatelyone to two inches (2.54 to 5.08 cm) in diameter. If it is intended forone or more of floor chases 319 to be used for gray or black waterdischarge, then those floor chases are preferably suitably sloped and ofa diameter appropriate to accommodate the discharged gray or blackwater, such as greater than approximately four inches (10.16 cm), forexample approximately six inches (15.24 cm). Floor chases 319 can beformed in the floor foam panels 314 by use of a circular hot wireappropriately positioned and displaced into the foam panels below thesurfaces of the panels, generally in the same manner described above inregard to the wall chases.

Preferably, the floor chases 319 are positioned to be aligned and tocommunicate with the wall chases 219 in wall component 200. Thus forexample, if wall chases 219 are spaced apart at approximatelytwenty-nine inch (73.7 cm) intervals, then the floor chases preferablyare also spaced apart at approximately twenty-nine inch (73.7 cm)intervals. In the manner shown in FIGS. 7A-7B, each floor chase 319intersects and communicates with a vertically oriented passage, floorchase connector 372, which in turn communicates with a respective wallchase 219 through a through-hole 291 in floor plate 220 of wallcomponent 200. This arrangement thus provides each of the floor chases319 with utility line routing access to a respective wall chase 219 andin turn, to utility service system 460 (in the particular embodimentshown, in situ channels 471) and ceiling chases 440. In a manner similarto that described above with regard to wall chases 219, apertures forcut-outs can be formed in floor component 300 to communicate with floorchases 319, thereby providing access to, for example, electrical serviceat a great number of locations across floor component 200.

Enclosure Component Relationships and Assembly for Transport

For ease of transport and maximum design flexibility, it is preferredthat there be a specific dimensional relationship among enclosurecomponents 155.

FIG. 2A shows a top schematic view of the type 1 structure 151 shown inFIG. 1A, and includes a geometrical orthogonal grid for clarity ofexplaining the preferred dimensional relationships among enclosurecomponents 155. The basic length used for dimensioning is indicated as“E” in FIG. 2A; the orthogonal grid overlaid in FIG. 2A is 24E long and12 E wide, and illustrates the relative dimensions of the components.

More particularly, in FIG. 2A the two long wall components 200 a areapproximately 24E long, and the two short wall components 200 b areapproximately 12E long. Each of ceiling portions 400 a, 400 b and 400 cis 24E long and 4E wide. The two floor portions 300 a and 300 b of type1 structure 151 are shown in FIGS. 2A and 3A. Each of floor components300 a and 300 b is 24E long; whereas floor component 300 a isapproximately 4E wide and floor component 300 b is approximately 8Ewide.

The shipping module 100 for type 1 structure 151, shown edge-on in FIG.3A, generally includes a fixed space portion 102 defined by ceilingcomponent 400 a, floor component 300 a, long wall component 200 a-R andtwo first wall portions 200 b-1 of short wall components 200 b. As shownin FIG. 2A, the remaining two portions of short wall components 200 b,second wall portions 200 b-2, are folded inward and positioned againstfixed space portion 102 (identified in FIG. 2A as wall portion 200 b-2 fwhen so folded and positioned). The three ceiling portions 400 a, 400 band 400 c of type 1 structure 151 are shown deployed in FIG. 1A. FIG.3A, the shipping module 100 for type 1 structure 151, depicts ceilingcomponents 400 b and 400 c stacked on top of the ceiling component 400 athat in part defines fixed space portion 102. Long wall component 200a-P, shown in FIGS. 2A and 3A, is pivotally secured to floor portion 300b at the location of horizontal axis 105, and is vertically positionedagainst the outside of second wall portions 200 b-2. In turn, floorportion 300 b is vertically positioned proximate to fixed space portion102, with long wall component 200 a-P pending (i.e., hanging) from floorportion 300 b between floor portion 300 b and second wall portions 200b-2.

Sizing the enclosure components 155 of type 1 structure 151 according tothe dimensional relationships disclosed above yields a compact shippingmodule 100, as can be seen from the figures. Thus shipping module 100,when dimensioned according to the relationships disclosed herein usingan “E” dimension (see FIG. 2A) of approximately 19.5 inches (49.5 cm),and when its components are stacked and positioned as shown in FIG. 3A,has an overall length of approximately 39 feet (11.89 meters), anoverall width of approximately 8.5 feet (2.59 meters) and an overallheight of approximately 12.7 feet (3.87 meters). These overalldimensions are approximately the same or less than a typical shippingcontainer.

Similarly, FIG. 2B shows a top schematic view of the type 2 finishedstructure 152 shown in FIG. 1B, and includes a geometrical orthogonalgrid for clarity of explaining the preferred dimensional relationshipsamong its enclosure components 155. The basic length used fordimensioning is indicated as “E” in FIG. 2B; the orthogonal gridoverlaid in FIG. 2B is approximately 8E long and 8E.

More particularly, in FIG. 2B the four wall components 200 s areapproximately 8E long, and each of ceiling portions 400 a, 400 b and 400c is approximately 8E long and 2.67E wide. The two floor portions 300 aand 300 b of finished structure 152 are shown in FIGS. 2B and 3B. Eachof floor components 300 a and 300 b is 8H long; whereas floor component300 a is approximately 3E wide and floor component 300 b isapproximately 5E wide.

The shipping module 100 for type 2 structure 152, shown edge-on in FIG.3B, also generally includes a fixed space portion 102 defined by ceilingcomponent 400 a, floor component 300 a, wall component 200 s-R, wallportion 200 s-1 and wall portion 200 s-4. As show in FIG. 2B, secondwall portion 200 s-2 is folded inward and positioned generally againstfixed space portion 102, whereas third wall portion 200 s-3 is foldedoutward and positioned generally against second wall portions 200 s-2(wall portions 200 s-2 and 200 s-3 are respectively identified in FIG.2B as portions 200 s-2 f and 200 s-3 f when so folded and positioned);so as to form an accordion fold having as its elements fixed spaceportion 102, second wall portion 200 s-2 and third wall portion 200 s-3.Fifth wall portion 200 s-5 is folded inward and positioned generallyagainst fixed space portion 102 (identified in FIG. 2B as wall portion200 s-5 f when so folded and positioned). The three ceiling components400 a, 400 b and 400 c are shown deployed in FIG. 1B. FIG. 3B, theshipping module 100 for type 2 structure 152, depicts ceiling components400 b and 400 c stacked on top of the ceiling component 400 a that inpart defines fixed space portion 102. Wall component 200 s-P, shown inFIGS. 2B and 3B, is pivotally secured to floor portion 300 b at thelocation of axis 105, and is vertically positioned against the outsideof wall portions 200 s-3 and 200 s-5. In turn, floor portion 300 b isvertically positioned proximate to fixed space portion 102, with longwall component 200 s-P pending from floor portion 300 b between floorportion 300 b and wall portions 200 s-3 and 200 s-5.

Sizing the enclosure components 155 of type 2 structure 152 according tothe dimensional relationships disclosed above yields a compact shippingmodule 100, as can be seen from the figures. Thus shipping module 100depicted in FIG. 3B, when dimensioned according to the relationshipsdisclosed herein using an “E” dimension (see FIG. 2B) of approximately29 inches (73.7 cm), and when its components are stacked and positionedas shown in FIG. 3B, has an overall length of approximately 19 feet(5.79 m), an overall width of approximately 8.5 feet (2.59 meters) andan overall height of approximately 12.7 feet (3.87 meters). Theseoverall dimensions are less than a typical shipping container.

The geometrical orthogonal grid referred also provides beneficialreference points for placement of floor chases 319, wall chases 219 andceiling chases 440. When such chases are placed for example at specific“E” intervals that coincide with the grid spacing being used, they areeasily located during structure finishing.

It is preferred that the fixed space portion 102 be in a relativelyfinished state prior to positioning (folding) together all other of thewall, ceiling and floor portions as described above. That is, the fixedspace portion 102 is preferably fitted during manufacture with allmechanical and other functionality that the structure 150 will require,such as kitchens, bathrooms, laundry rooms, HVAC closets, fireplaces,clothing closets, storage areas, corridors, etc. A temporary member 103(shown in FIG. 3A) provides support during shipping of type 1 structure151 and is removed after delivery (there is no comparable temporarymember utilized for shipping type 2 structure 152). Preferably afterfixed space portion 102 is finished to the desired state, the remainingcomponents are folded and positioned against fixed space portion 102 asdescribed above. The components, so folded and positioned, permit thebuilder, in effect, to erect finished structure 150 simply by“unfolding” (deploying) the positioned components of shipping module100.

As exemplified by long wall component 200 a in FIG. 5A, each of thewall, floor and ceiling components 200, 300 and 400, and/or the portionsthereof, can be sheathed in protective film 177 during fabrication andprior to forming the shipping module 100. Alternatively or in addition,the entire shipping module 100 can be sheathed in a protective film.These protective films accordingly constitute a means for protecting theshipping module 100 and components 200, 300 and 400 during shipping. Inaddition to the protection they give to the module and its components,such protective films have the added benefit of increasing theresistance of the components to such flexural and torsional stresses asmay occur during transport of the components. These protective filmsconstitute further means for rigidifying wall component 200 to improveits robustness during transport and erection of the structure at theconstruction site. It is preferred that such protective films remain inplace until after the shipping module 100 is at the construction site,and then removed as required to facilitate enclosure componentdeployment and finishing.

Shipping Module Transport

The shipping module is shipped to the building site by appropriatetransport means. One such transport means is disclosed in U.S. PatentApplication Publication No. US 2019/0100127 A1, filed Sep. 27, 2018, andin International Publication No. WO 2019/070485 A1; the contents ofwhich are incorporated by reference as if fully set forth herein,particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2Dthereof. As an alternative transport means, shipping module 100 can beshipped to the building site by means of a conventional truck trailer ora low bed trailer (also referred to as a lowboy trailer).

Structure Deployment and Finishing

At the building site, shipping module 100 is positioned over its desiredlocation, such as over a prepared foundation; for example, a pouredconcrete slab, a poured concrete or cinder block foundation, sleeperbeams or concrete posts or columns. This can be accomplished by using acrane, either to lift shipping module 100 from its transport and move itto the desired location, or by positioning the transport means over thedesired location, lifting shipping module 100, then moving the transportmeans from the desired location, and then lowering shipping module 100to a rest state at the desired location. Particularly suitable equipmentand techniques for facilitating the positioning of a shipping module 100at the desired location are disclosed in U.S. Nonprovisional patentapplication Ser. No. 16/786,315 entitled “Equipment and Methods forErecting a Transportable Foldable Building Structure,” having the sameinventors and filed on the same date as the subject application. Thecontents of that U.S. Nonprovisional patent application Ser. No.16/786,315 entitled “Equipment and Methods for Erecting a TransportableFoldable Building Structure,” having the same inventors and filed on thesame date as the subject application, are incorporated by reference asif fully set forth herein, particularly including the equipment andtechniques described for example at paragraphs 126-128 and in connectionwith FIGS. 11A and 11B thereof.

Following positioning of shipping module 100 at the building site, theappropriate portions of wall, floor and ceiling components 200, 300 and400 are “unfolded” (i.e., deployed) according to the sequences describedabove to yield finished structure 150.

For type 1 structure 151, unfolding (enclosure component and componentportion deployment) occurs in the following sequence: (1) floor portion300 b is pivotally rotated about horizontal axis 305 shown in FIG. 3A toan unfolded position, (2) wall component 200 a-P is pivotally rotatedabout horizontal axis 105 shown in FIG. 3A to an unfolded position, (3)wall portions 200 b-2 of short wall components 200 b are pivotallyrotated about vertical axes 191 shown in FIG. 2A to unfolded positions,and (4) ceiling portions 400 b and 400 c are pivotally rotated abouthorizontal axes 405 a and 405 b respectively to their unfoldedpositions.

For type 2 structure 152, unfolding occurs in the following sequence:(1) floor portion 300 b is pivotally rotated about horizontal axis 305shown in FIG. 3B to an unfolded position, (2) wall component 200 s-P ispivotally rotated about horizontal axis 105 shown in FIG. 3B (behindperimeter board 312) to an unfolded position, (3) wall portions wallportions 200 s-2, 200 s-3 and 200 s-5 are pivotally rotated aboutvertical axes 192, 193 and 194 respectively to unfolded positions, and(4) ceiling portions 400 b and 400 c are pivotally rotated abouthorizontal axes 405 a and 405 b respectively to unfolded positions. Amobile crane can be used to assist in the deployment of certain of theenclosure components 155, specifically ceiling portions 400 b and 400 c,floor portion 300 b, as well as the wall component 200 pivotally securedto floor portion 300 b (200 a-P for type 1 structure 151, 200 s-P fortype 2 structure 152). Alternatively, particularly suitable equipmentand techniques for facilitating the deployment of enclosure components155 are disclosed in U.S. Nonprovisional patent application Ser. No.16/786,315 entitled “Equipment and Methods for Erecting a TransportableFoldable Building Structure,” having the same inventors and filed on thesame date as the subject application. The contents of that U.S.Nonprovisional patent application Ser. No. 16/786,315 entitled“Equipment and Methods for Erecting a Transportable Foldable BuildingStructure,” having the same inventors and filed on the same date as thesubject application, are incorporated by reference as if fully set forthherein, particularly including the equipment and techniques describedfor example at paragraphs 132-145 and depicted in FIGS. 12A-14B thereof.

Notably, baseboard 310 in appropriate locations functions as a “stop” toarrest the unfolding of a wall component or a wall portion at itsintended deployed position. Thus for example, baseboard 310 in FIG. 3A,depicting a type 1 structure 151, arrests the unfolding of the long wall200 a-P shown in the figure, when long wall 200 a-P is fully deployed inits desired vertical position. Likewise, perimeter board 312 in FIG. 3B,depicting a type 2 structure 152, performs a similar function withrespect to a wall 200 s-P, and also with respect to wall portions 200s-2, 200 s-3 and 200 s-5. Further, baseboard 310 provides a structurefor securing a deployed wall component in its deployed position; thusfor example, baseboard 310 is provided in FIG. 6A with pluralspaced-apart apertures 311 through which fasteners may be inserted tosecure long wall 200 a in place.

After deployment, the enclosure components 155 are secured together toform finished structure 150, shown in FIGS. 1A and 1B. If any temporaryhinge mechanisms have been utilized, then these temporary hingemechanisms can be removed if desired and the enclosure components 155can be secured together. If certain of the enclosure component perimeterstructures disclosed in U.S. Nonprovisional patent application Ser. No.16/786,202 entitled “Enclosure Component Perimeter Structures,” havingthe same inventors and filed on the same date as the subjectapplication, have been utilized, specifically those described forexample at paragraphs 121-157 and in FIGS. 12-15, then certain finishingoperations preferably are performed in regard to such structures, asdescribed therein. The contents of that U.S. Nonprovisional patentapplication Ser. No. 16/786,202 entitled “Enclosure Component PerimeterStructures,” having the same inventors and filed on the same date as thesubject application, are incorporated by reference as if fully set forthherein, particularly including the finishing operations performed inregard to enclosure component perimeter structures, described forexample at paragraphs 179-182 and in FIGS. 13C, 13F, 14C, 14E, 15 and 17thereof.

After deployment and securing of the enclosure components 155, one ormore pre-selected chases located in wall components 200 (connecting andvertical wall chases 207 and 219), in floor component 300 (floor chases319) and in ceiling component 400 (ceiling chases 440) can be wired andconnected to the appropriate utility line in utility channel 460, suchas electrical loop 208, as described above, and loop 208 in turn can beconnected to the electric utility's service drop, thus energizing theelectrical service of finished structure 150.

Prior to, during or following deployment and securing of the enclosurecomponents 155, as desired, apertures 202, 204 for one or more doors andwindows are cut at desired locations in the wall components 200, andappropriate door and window assemblies are positioned and fastened inthe apertures 202, 204. Additional municipal hook-ups are made to waterand sewer lines to complete structure 150, as relevant here.

Building Configuration Options

As discussed above, any number of structures 150 can be positionedtogether at the desired site, to yield a multitude of differentstructural configurations. Interior staircases for such multi-storystructures can be provided during manufacture in fixed space portion102, together with insertion of an appropriate access aperture inceiling component 400, or can be added after erection. Likewise, apitched roof and other architectural additions can be deliveredseparately from shipping module 100 or fabricated on-site, andpositioned onto ceiling component 400 of finished structure 150.

For example, two or more finished structures 150 can be erected so thata wall component 200 of one structure is placed adjacent a wallcomponent 200 of the other structure. The builder can then cut aperturesin those juxtaposed regions to connect the two structures in accordancewith the purchaser's design choices. As one example, FIG. 10 depicts thefloor plan of three finished structures, 150 a, 150 b and 150 c, each ofa type 2 structure 152, arranged side-by-side to yield one housing unitwith three rooms. The laminate multi-layer design of enclosurecomponents 155 affords such location flexibility as to permit, in thisparticular instance, locating window apertures 204 in each wallcomponent 200 s, and thereby provide windows on all four sides of eachroom.

Finished structures 150 can also be stacked, one on top of the other, tocreate multi-story structures. Using two type 2 structures 152, FIG. 11depicts a finished structure 150 e positioned on top of a finishedstructure 150 d to yield a two story structure. The laminate multi-layerdesign of enclosure components 155 permits a wide variety ofcustomization options. Thus as shown in FIG. 10 , there is provided agarage aperture 203 in addition to door aperture 202 on the first level,as well as a door aperture 202 (not visible) on the second level, whichis accessed via exterior stairway 201. Furring strips 418 can beprovided on ceiling top surface 402 along the first and secondlongitudinal ceiling edges 406 and 416, along the second transverse andfirst transverse ceiling edges 408 and 410, and as desired spaced apartat select intervals within the perimeter of those edges. Such furringstrips 418, shown in FIG. 6C, provide an air barrier between the levelsof the multi-story structure. As necessary, means can be utilized tosecure stacked finished structures 150 each to the other, such as by useof steel reinforcing plates fastened at spaced-apart locations to joinan overlying floor component 300 to an underlying ceiling component 400.

Where four or more finished structures 150 are stacked in a 2×2 array,their baseboards 310 (shown in FIG. 6A) if utilized in appropriatelocations will abut each other, thereby providing a space between thestacked finished structures 150. For example, baseboard 310 can beapproximately two inches (5.08 cm) in thickness (the dimension parallelto the floor component 300). Such a thickness provides a space betweenadjacent finished structures 150 of approximately four inches (10.16 cm)in width, which can be utilized for running utility lines betweenfloors, such as a plumbing stack (vertical main used for liquid wastewater discharge) or electrical mains. Such utility lines can be accessedas desired by forming apertures in shoulder beams 435 at appropriatelocations.

The foregoing detailed description is for illustration only and is notto be deemed as limiting the invention, which is defined in the appendedclaims.

What is claimed is:
 1. A foldable building structure comprising: a fixedspace portion including a first floor portion having a thickness todefine an interior portion of the first floor portion, a first ceilingportion having a thickness to define an interior portion of the firstceiling portion, and a first wall portion having a thickness to definean interior portion of the first wall portion; the foldable buildingstructure further comprising: a second ceiling portion having athickness to define an interior portion of the second ceiling portion,the second ceiling portion movable between a folded position that isproximate to the fixed space portion and a deployed position; a thirdceiling portion having a thickness to define an interior portion of thethird ceiling portion, the third ceiling portion movable between afolded position that is proximate to the fixed space portion and adeployed position; the second and third ceiling portions movable fromtheir respective folded positions to their respective deployed positionsto form with the first ceiling portion a ceiling component of thebuilding structure when in their deployed positions, the ceilingcomponent having a periphery; and the first, second and third ceilingportions each defining sections of a utility service system in theinterior portions of the first, second and third ceiling portions, whichsections are configured to form a closed loop utility service system inthe interior portions of the ceiling component when the second and thirdceiling portions are in their deployed positions, the utility servicesystem being located proximate the periphery of the ceiling componentand adapted for containing utility lines.
 2. The foldable buildingstructure as in claim 1, further comprising foam material in theinterior portions of the first, second and third ceiling portions, andthe utility service system is positioned in the foam material of thefirst, second and third ceiling portions.
 3. The foldable buildingstructure as in claim 2, wherein the utility service system comprises afirst channel and a second channel spaced from the first channel andsubstantially parallel to the first channel.
 4. The foldable buildingstructure as in claim 3, wherein the first channel and the secondchannel are substantially circular in cross section.
 5. The foldablebuilding structure as in claim 1, wherein: the first ceiling portion hasa first plurality of spaced-apart elongate ceiling chases in itsinterior portion for containing utility lines; the second ceilingportion has a second plurality of spaced-apart elongate ceiling chasesin its interior portion for containing utility lines; the third ceilingportion has a third plurality of spaced-apart elongate ceiling chases inits interior portion for containing utility lines; one or more of thefirst, one or more of the second and one or more of the third pluralityof spaced-apart elongate ceiling chases having a communicatingrelationship with the utility service system formed when the second andthird ceiling portions are in their deployed positions to form with thefirst ceiling portion the ceiling component of the building structure.6. The foldable building structure as in claim 5, wherein each of thefirst ceiling portion, the second ceiling portion and the third ceilingportion each has a plurality of spaced-apart elongate ceiling chasesegments in its interior portion, adapted to form a fourth plurality ofspaced-apart elongate ceiling chases for containing utility lines andhaving a communicating relationship with the utility service systemformed when the second and third ceiling portions are in their deployedpositions, the fourth plurality of spaced-apart elongate ceiling chasesoriented substantially perpendicularly to the first, second and thirdplurality of spaced-apart elongate ceiling chases.
 7. The foldablebuilding structure of claim 1, further comprising: a second wall portionhaving a thickness to define an interior portion of the second wallportion, which second wall portion is movable between a folded positionthat is proximate to the fixed space portion and a deployed position toform with the first wall portion all or part of a wall component of thebuilding structure when in its deployed position; the first wall portionhaving a first plurality of spaced-apart elongate wall chases in itsinterior portion for containing utility lines; the second wall portionhaving a second plurality of spaced-apart elongate wall chases in itsinterior portion for containing utility lines; and one or more of thefirst and one or more of the second spaced-apart wall elongate chaseshaving a communicating relationship with the utility service systemformed when the second and third ceiling portions are in their deployedpositions to form with the first ceiling portion the ceiling componentof the building structure.
 8. The foldable building structure as inclaim 7, wherein each of the first wall portion and the second wallportion has a wall chase segment in its interior portion, the wall chasesegments adapted to form a connecting wall chase for containing utilitylines when the first wall portion is in its deployed position, theconnecting wall chase communicating with each of the first and secondspaced-apart elongate wall chases when the first wall portion is in itsdeployed position.
 9. The foldable building structure of claim 7,further comprising: a second floor portion having a thickness to definean interior portion of the second floor portion, the second floorportion is movable between a folded position that is proximate to thefixed space portion and a deployed position to form with the first floorportion a floor component of the building structure; the first floorportion having a first plurality of spaced-apart elongate floor chasesin its interior portion for containing utility lines; the second floorportion having a second plurality of spaced-apart elongate floor chasesin its interior portion for containing utility lines; one or more of thefirst plurality of spaced-apart elongate floor chases, and one or moreof the second plurality of spaced-apart elongate floor chases, having acommunicating relationship with a respective first and second elongatewall chases of the first plurality of spaced-apart elongate wall chasesand/or the second plurality of spaced-apart elongate wall chases, whenthe second wall portion is in its deployed position to form with thefirst wall portion all or part of a wall component of the buildingstructure, and when the second floor portion is in its deployed positionto form with the first floor portion the floor component of the buildingstructure.
 10. The foldable building structure as in claim 9, whereineach of the first floor portion and the second floor portion each has aplurality of spaced-apart elongate floor chase segments in its interiorportion, adapted to form a third plurality of spaced-apart elongatefloor chases for containing utility lines when the second floor portionis in its deployed position, the third plurality of spaced-apartelongate floor chases oriented substantially perpendicularly to thefirst and second plurality of spaced-apart elongate floor chases.